U.S. patent number 11,375,849 [Application Number 16/447,897] was granted by the patent office on 2022-07-05 for system and method for cooking a food product.
This patent grant is currently assigned to Creator, Inc.. The grantee listed for this patent is Creator, Inc.. Invention is credited to Michael Balsamo, Noe Esparza, Steven Frehn, Andrew Stulc, Alexandros Vardakostas, Matthew Williams.
United States Patent |
11,375,849 |
Balsamo , et al. |
July 5, 2022 |
System and method for cooking a food product
Abstract
A system for cooking a food product may include a base, a hub, a
plurality of cooking plates, a plurality of wipers, a spatula
assembly, a backstop, an infrared (IR) sensor, and a proximity
sensor. The hub may rotate relative to the base. The cooking plates
are rotatable with the hub among a plurality of cooking stations.
The wipers extend outward from a periphery of the hub. The backstop
may be fixed relative to the base and may include one or more
additional wipers contacting one or more of the cooking plates. The
spatula assembly may cooperate with the backstop to pick up the
food product from the one of the cooking stations. The IR sensor
may measure a temperature of the food product on one of the cooking
plates. The proximity sensor may detect a position of the food
product on one of the cooking plates.
Inventors: |
Balsamo; Michael (San
Francisco, CA), Frehn; Steven (San Francisco, CA),
Vardakostas; Alexandros (San Francisco, CA), Esparza;
Noe (San Francisco, CA), Stulc; Andrew (Spokane, WA),
Williams; Matthew (San Francisco, CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Creator, Inc. |
San Francisco |
CA |
US |
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Assignee: |
Creator, Inc. (San Francisco,
CA)
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Family
ID: |
1000006413502 |
Appl.
No.: |
16/447,897 |
Filed: |
June 20, 2019 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20190298104 A1 |
Oct 3, 2019 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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15785410 |
Oct 16, 2017 |
10743710 |
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15157267 |
Oct 17, 2017 |
9788687 |
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62687792 |
Jun 20, 2018 |
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62162798 |
May 17, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H05B
6/1272 (20130101); A23L 5/15 (20160801); A47J
37/0611 (20130101); H05B 6/065 (20130101); H05B
6/12 (20130101); A47J 37/046 (20130101); A47J
37/043 (20130101) |
Current International
Class: |
A47J
37/06 (20060101); H05B 6/12 (20060101); A23L
5/10 (20160101); H05B 6/06 (20060101); A47J
37/04 (20060101) |
Field of
Search: |
;99/423,424,427,374,391,395 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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427687 |
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Apr 2009 |
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AT |
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201987268 |
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Sep 2011 |
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CN |
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102727070 |
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Oct 2012 |
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CN |
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1961352 |
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Aug 2008 |
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EP |
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H06007127 |
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Jan 1994 |
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JP |
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H07232807 |
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Sep 1995 |
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JP |
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H07255604 |
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Oct 1995 |
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JP |
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H07313373 |
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Dec 1995 |
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JP |
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H0871003 |
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Mar 1996 |
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JP |
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3178899 |
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Jun 2001 |
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JP |
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5011090 |
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Aug 2012 |
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JP |
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Other References
Office Action for CN Application No. 201680041865X; dated Mar. 24,
2020; 8 pages. cited by applicant .
International Search Report and Written Opinion for PCT Application
No. PCT/US2016/032915, dated Aug. 18, 2016, 13 pages. cited by
applicant .
Search Report for EP Application No. 16 79 7163; dated Jan. 10,
2019; 5 pages. cited by applicant.
|
Primary Examiner: Alexander; Reginald
Attorney, Agent or Firm: Miller Johnson
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent
application Ser. No. 15/785,410 filed Oct. 16, 2017, which is a
continuation of U.S. patent application Ser. No. 15/157,267 filed
May 17, 2016 (now U.S. Pat. No. 9,788,687), which claims the
benefit of U.S. Provisional Application No. 62/162,798 filed May
17, 2015. This application also claims the benefit of U.S.
Provisional Application No. 62/687,792 filed Jun. 20, 2018. The
entire disclosures of the applications referenced above are
incorporated by reference.
Claims
What is claimed is:
1. A system for cooking a food product, the system comprising: a
base; a hub rotatable relative to the base; a plurality of cooking
plates rotatable with the hub among a plurality of cooking
stations; a backstop fixed relative to the base at one of the
cooking stations, wherein the backstop includes one or more wipers
contacting one or more of the cooking plates; and a spatula
assembly configured to cooperate with the backstop to pick up the
food product from the one of the cooking stations.
2. The system of claim 1, further comprising a plurality of wipers
extending outward from a periphery of the hub.
3. The system of claim 2, wherein: the base include a grease
trough, and distal ends of the wipers include trough wipers
received in the grease trough.
4. The system of claim 1, wherein: the spatula assembly includes a
first actuator, a second actuator, a first arm, a second arm, and a
spatula, the second actuator, the first arm, the second arm, and
the spatula are rotatable about a first rotational axis, the first
arm, the second arm, and the spatula are rotatable about a second
rotational axis, and the second arm and the spatula are rotatable
about a third rotational axis.
5. The system of claim 4, wherein the second and third rotational
axes are parallel to each other and perpendicular to the first
rotational axis.
6. The system of claim 1, further comprising an infrared (IR) fixed
relative to the base and configured to measure a temperature of the
food product on one of the cooking plates.
7. The system of claim 1, further comprising a proximity sensor
fixed relative to the base and configured to detect a position of
the food product on one of the cooking plates.
Description
FIELD
The present disclosure relates generally to the field of food
preparation and more specifically to a new and useful system and
method for cooking a food product in the field of food
preparation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a system;
FIG. 2 is a schematic representation of one variation of the
system;
FIG. 3 is a schematic representation of one variation of the
system;
FIG. 4 is a schematic representation of one variation of the
system;
FIG. 5 is a schematic representation of one variation of the
system;
FIG. 6 is a schematic representation of one variation of the
system;
FIG. 7 is a flowchart representation of a method;
FIG. 8 is a flowchart representation of one variation of the
method;
FIG. 9 is a plan view of another system;
FIG. 10 is a perspective view of the system of FIG. 9;
FIG. 11 is a side view of the system of FIG. 9;
FIG. 12 is a plan view of the system with first and second upper
induction heads removed;
FIG. 13 is a partial cross-sectional view of a wiper engaging a
barrier and a grease trough;
FIG. 14 is a side view of the system with first and second upper
induction heads removed;
FIG. 15 is a perspective view of the system with first, second, and
third upper induction heads removed; and
FIG. 16 is a perspective view of a backstop member.
DETAILED DESCRIPTION
The following description of the embodiments of the invention is
not intended to limit the invention to these embodiments but rather
to enable a person skilled in the art to make and use this
invention.
1. System
As shown in FIGS. 1 and 2, a system 100 for cooking a meat patty
includes: a set of griddle modules 110, each griddle module 110 in
the set of griddle modules 110 including a lower plate 111
configured to receive a meat patty and an upper plate 112 arranged
over the lower plate 111 and configured to contact the meat patty;
and a set of induction stations 120 including an entry induction
station 121 and an exit induction station 123, each induction
station in the set of induction stations 120 including 1) a lower
coil 124 configured to inductively couple to an adjacent lower
plate 111 and 2) an upper induction head 126 including an upper
coil 125 configured to inductively couple to an adjacent upper
plate 112. The system 100 also includes: a base 130 including a
barrier, housing lower coils 124 of the set of induction stations
120 on a first side of the barrier, and supporting each upper
induction head 126 in alignment with a lower coil 124 of a
corresponding induction station offset on a second side of the
barrier opposite the first side; and a conveyor system including 1)
a hub 140 supporting lower plates 111 of the set of griddle modules
110 between the barrier and the upper induction heads 126, the
lower plates 111 offset from the barrier and 2) a hub actuator
arranged within the base 130 and sequentially indexing each griddle
module 110 in the set of griddle modules 110 from the entry
induction station 121 to the exit induction station 123. The system
100 further includes: a retrieval system including a paddle and a
retrieval actuator, the retrieval actuator selectively advancing
the paddle across a lower plate 111 in the exit induction station
123 to collect a patty from the lower plate 111.
As shown in FIGS. 5 and 6, one variation of the system 100 for
cooking a food product includes: a first griddle; a second griddle;
a set of induction stations 120; a base 130; a hub 140; and a
controller 180. In this variation, the first griddle module 110
includes a lower plate 111 configured to receive a first food
product and an upper plate 112 arranged over the lower plate 111
and configured to contact the first food product. The set of
induction stations 120 includes an entry induction station 121 and
an exit induction station 123, wherein each induction station in
the set of induction stations 120 includes a lower coil 124
configured to inductively couple to the lower plate 111 when the
first griddle module 110 is arranged in the induction station and
an upper coil 125 configured to inductively couple to the upper
plate 112 when the first griddle module 110 is arranged in the
induction station. The base 130 includes a barrier, is configured
to support a lower coil 124 of an induction station on a first side
of the barrier, and is configured to support an upper coil 125 of
an induction station on a second side of the barrier opposite and
aligned with the lower coil 124 of the induction station for each
induction station in the set of induction stations 120. The hub
140: is configured to support the lower plate 111 and the upper
plate 112 of the first griddle module 110 between the barrier and
upper coils 125 of the induction stations with the lower plate 111
offset above the barrier and the upper plate 112 offset below upper
coils 125 of the induction stations; and is configured to
sequentially position the first griddle module 110 through the set
of induction stations 120 from the entry induction station 121 to
the exit induction station 123. In this variation, the controller
180 is configured to drive lower coils 124 and upper coils 125 of
the set of induction stations 120 based on a position of the first
griddle module 110 within the set of induction stations 120 to heat
the first food product between the lower plate 111 and the second
plate.
2. Method
As shown in FIGS. 7 and 8, a method S100 for cooking a meat patty
includes: elevating an upper induction head at an entry station to
separate a first upper plate from a first lower plate at the entry
station in Block S110; dispensing a meat patty onto the lower plate
in Block S112; at a first time, powering a lower coil at the entry
station to induction heat the first lower plate and powering an
upper coil at the entry station to induction heat the first upper
plate in Block S120; disabling the upper and lower coils at the
entry station in Block S130; indexing a hub to shift the first
lower plate and the first upper plate to an intermediate station
and to shift a second lower plate and a second upper plate to the
entry station in Block S140; at a second time succeeding the first
time, powering a lower coil at the intermediate station to
induction heat the first lower plate and powering an upper coil at
the intermediate station to induction heat the first upper plate in
Block S122; disabling the upper and lower coils at the intermediate
station in Block S132; indexing the hub to shift the first lower
plate and the first upper plate to an exit station in Block S142;
at a third time succeeding the second time, powering a lower coil
at the exit station to induction heat the first lower plate and
powering an upper coil at the intermediate station to induction
heat the first upper plate in Block S124; elevating an upper
induction head at the exit station to separate the first upper
plate from the first lower plate at the exit station in Block S160;
and removing the meat patty from the first lower plate at the exit
station in Block S162.
One variation of the method 100 includes: separating a first upper
plate of a first griddle module from a first lower plate of the
first griddle module positioned within an entry induction station
in Block S110; dispensing a first food product onto the first lower
plate in Block S112; during a first period of time, driving a lower
coil in the entry induction station to heat the first lower plate
and driving an upper coil in the entry induction station to heat
the first upper plate in Block S120; during a second period of time
succeeding the first period of time, disabling the lower coil and
the upper coil in the entry induction station in Block S130; during
the second period of time, positioning the first griddle module
within an intermediate induction station in Block S140; during a
third period of time succeeding the second period of time, driving
a lower coil in the intermediate induction station to heat the
first lower plate and driving an upper coil in the intermediate
induction station to heat the first upper plate in Block S122;
during a fourth period of time succeeding the third period of time,
disabling the lower coil and the upper coil in the intermediate
induction station in Block S132; during the fourth period of time,
positioning the first griddle module within an exit induction
station in Block S142; during a fifth period of time succeeding the
fourth period of time, driving a lower coil in the exit induction
station to heat the first lower plate and driving an upper coil in
the exit induction station to heat the first upper plate in Block
S124; at a sixth time succeeding the fifth period of time,
separating the first upper plate from the first lower plate of the
first griddle module positioned within the exit induction station
in Block S160; and removing the first food product from the first
lower plate in Block S162.
The foregoing variation of the method 100 can also include: during
the third period of time: separating a second upper plate of a
second griddle module from a second lower plate of the second
griddle module positioned within the entry induction station,
dispensing a second food product onto the second lower plate, and
driving the lower coil in the entry induction station to heat the
second lower plate and driving the upper coil in the entry
induction station to heat the second upper plate; during the fourth
period of time, disabling the lower coil and the upper coil in the
entry induction station; during the fourth period of time,
simultaneously positioning the second griddle module within the
intermediate exit induction station; and during the fifth period of
time, driving the lower coil in the intermediate induction station
to heat the second lower plate and driving the upper coil in the
intermediate induction station to heat the second upper plate.
3. Applications
The system 100 for cooking a food product (e.g., a hamburger patty,
a steak) functions to receive a food product between upper and
lower plates of a griddle module, to compress the food product
between the upper and lower plates of the griddle module, to
sequentially advance the griddle module through each induction
station in a set of induction stations, and to sequentially power
upper and lower induction coils of each induction station based on
the position of the griddle module to heat the upper and lower
plates of the griddle module, thereby heating (e.g., cooking) the
food product. The system 100 then removes the food product from the
griddle module once the griddle module has entered or passed
through a last induction station.
The system 100 can also include a set of (e.g., five) griddle
modules, such as one griddle module for each induction station. For
example, the system 100 can receive a first food product at a first
griddle module arranged in an entry induction station while a
second, a third, and a fourth food product are heated between upper
and lower plates of second, third, and fourth griddle modules in
second, third, and fourth induction stations, respectively, and
while a fifth food product is removed from a fifth griddle module
in an exit induction station. In this example, once the first food
product is inserted into the first griddle module and initially
heated in the first induction station, the system 100 can
deactivate all coils in all induction stations before indexing the
griddle modules forward in order to position the first griddle
module in the second induction station, to position the second
griddle module in the third induction station, to position the
third griddle module in the fourth induction station, to position
the fourth griddle module in the exit induction station, and to
position the fifth griddle module in the entry induction station.
As the second induction station heats the first food product
between the upper and lower plates of the first griddle module, the
system 100 places a sixth food product into the fifth griddle
module in the entry induction station and removes the fourth food
product from the fourth griddle module in the exit induction
station. The system 100 can then repeat this process over time to
continuously receive food products at griddle modules in the entry
induction station, to sequentially heat (or cook) food products
from the entry induction station through the exit induction
station, and to retrieve heated (or cooked) food products from
griddle modules in the exit induction station. In this example, the
system 100 can receive a sequence of hamburger patties from a patty
grinding system, sequentially insert hamburger patties into griddle
modules in the entry induction station, simultaneously cook
multiple hamburger patties to various doneness levels at each
induction station, and remove done hamburger patties from griddle
modules at the exit induction station.
As a griddle module containing a food product is indexed from the
entry induction station through to the exit induction station, as
shown in FIG. 7, the system 100 can also modulate a power output at
each induction station in order to achieve a target doneness for
the food product. For example, when the griddle module in the entry
induction station receives a hamburger patty assigned a medium
doneness level, the system 100 can implement closed-loop feedback
techniques to modulate the power outputs of the upper and lower
coils in the entry induction station based on outputs of
temperature sensors thermally coupled to the upper and lower plates
in the griddle module in order to maintain a target entry stage
temperature for a medium doneness level. In this example, once the
griddle module is indexed to a second induction station, the system
100 can again implement closed-loop feedback techniques to modulate
the power outputs of the upper and lower coils in a second
induction station based on outputs of temperature sensors thermally
coupled to the upper and lower plates in the griddle module in
order to maintain a target second stage temperature for a medium
doneness level. In this example, the system 100 can repeat this
process until the hamburger patty is fully cooked to a medium
doneness level at the exit induction.
Furthermore, the system 100 can actively control compression of a
food product between the upper and lower plates of a griddle module
in order to achieve a doneness level assigned to the food product.
For example, the system 100 can include a compression actuator 128
configured to drive the upper and lower plates of a griddle module
together to increase the cook rate of a hamburger patty arranged in
the griddle module, thereby yielding a hamburger patty of a greater
doneness level upon completion of a cook cycle. The system 100 can
similarly control the compression actuator 128 to separate the
upper and lower plates of a griddle module in order to decrease the
cook rate of a hamburger patty arranged in the griddle module,
thereby yielding a hamburger patty of a lesser doneness level upon
completion of a cook cycle. Alternatively, the system 100 can
actively adjust a stop in a griddle module in order to set a
minimum offset distance between the bottom face of an upper plate
and the top face of a corresponding lower plate of a griddle module
based on a doneness level assigned to a food product. The system
100 can thus control one or more cook parameters, such as
temperature and compression, to cook a food product--within a
griddle module--to a target doneness or to a target temperature
independent of other food products cooking in other griddle modules
in the system 100.
Upon completion of a cook cycle at a griddle module (i.e., upon
advancement of the griddle module from the entry induction station
through to the exit induction station), the system 100 can then
remove a heated or cooked food product from the griddle module. For
example, for the food product that includes a hamburger patty, the
system 100 can remove the hamburger patty from a griddle module in
the exit induction station and dispense the hamburger patty onto a
hamburger bun nearby in preparation for delivering a completed
hamburger to a patron according to a custom hamburger order
recently submitted by the patron.
The system 100 is described herein as a system for cooking raw
hamburger patties. However, the system 100 can additionally or
alternatively cook or heat: vegetable patties; raw patties of
ground fish, poultry, pork, lamb, or bison, etc.; raw beef, fish,
bison, or lamb, etc. steaks; raw chicken breasts; cooked or
uncooked sausage; and/or any other raw, semi-cooked, or cooked food
product of any other geometry and can dispense such a food product
onto any other cooking surface, heating surface, hamburger bun,
bread slice, bed of greens, plate, bowl, or other container or
surface upon completion of a cook cycle.
4. Automated Food Assembly Apparatus
The system 100 can function as a subsystem within an automated
foodstuff assembly apparatus 200 including one or more other
subsystems that automatically prepare, assemble, and deliver
foodstuffs according to custom food orders submitted by local
and/or remote patrons. For example, the automated foodstuff
assembly apparatus 200 can include: a bun dispenser and slicing
subsystem that slices and dispenses a bun from a bun hopper; a bun
buttering subsystem that applies butter to each side of the sliced
bun prior to toasting the halves of the bun; a bun toaster
subsystem that toasts each side of the bun; a topping module that
loads a custom set of toppings in custom quantities onto the bun
heel according to topping specifications in a custom food order
received from a patron; a condiment subsystem that loads condiments
onto the bun crown according to condiment specifications in the
custom food order; a patty grinding system that grinds a quantity
of raw meat (e.g., based on a custom patty size and a custom meat
blend specified in the custom food order) and that presses this
quantity of meat into a custom hamburger patty (e.g., to a
compression level corresponding to a custom doneness level
specified in the custom food order); the system 100 functioning as
a patty cooking subsystem that cooks the hamburger patty received
from the patty grinding system according to the custom doneness
level specified in the custom food order and dispenses the cooked
hamburger patty onto the bun heel; and a boxing subsystem that
closes the completed hamburger within a paper box for subsequent
delivery to the corresponding patron.
The system 100 can cook hamburger patties or veggie patties (e.g.,
from raw or cooked vegetables) for assembly into other types of
assembled foodstuffs, such as sandwiches, hotdogs, burritos, tacos,
salads, or wraps, etc. according to custom food orders submitted by
patrons to a restaurant, food truck, convenience store, grocery
store, or food kiosk, etc. housing an automated foodstuff assembly
apparatus. The system 100 can therefore be incorporated into an
automated foodstuff assembly apparatus 200 to automatically cook
whole or ground meat or vegetable products once an order for a
hamburger (or other foodstuff) is submitted by a patron and while
other components of the patron's order are processed at the
automated foodstuff assembly apparatus.
5. Cook Cycle
The system executes the method 100 during a cook cycle to receive a
sequence of food products (e.g., hamburger patties) and to move
each food product through the set of induction stations to
simultaneously but independently cook each food product before
releasing a food product, such as onto a corresponding hamburger
bun or into a box.
Block S110 of the method 100 recites separating a first upper plate
of a first griddle module from a first lower plate of the first
griddle module positioned within an entry induction station.
Generally, in Block S110, the system 100 separates an upper plate
from a lower plate of a first griddle module in the entry induction
station in preparation to load the first griddle module with a food
product. In one implementation, the entry induction station
includes an upper induction head that houses the upper coil of the
entry induction station and an entry elevation actuator 127
configured to (linearly or arcuately) lift the upper induction head
of the entry induction station away from the base. For example, the
upper induction head in the entry induction station can run
vertically on a set of linear rails, and the entry elevation
actuator can include a linear actuator oriented vertically between
the base and the upper induction head and configured to drive the
upper induction head vertically along linear rails. In this
implementation, a first receiver coupled to the hub and supporting
the upper plate of the first griddle module includes a skid 116
that contacts the upper induction head (or vice versa) such that
the first receiver and upper plate rise with the upper induction
head when the entry elevation actuator lifts the entry induction
head, thereby separating the upper plate of the first griddle
module from its corresponding lower plate in preparation to receive
a food product in Block 110. Alternatively, the system 100 can
include an entry elevation actuator at the entry induction station
that engages the upper plate of the first griddle module directly
(or that engages the first receiver of the hub directly) to lift
the upper plate away from the lower plate of the first griddle
module. Yet alternatively, the system 100 can include one entry
elevation actuator per griddle module and mounted to the hub
between the hub and the upper plate of a corresponding griddle
module. However, the system 100 can include any other one or more
actuators, linkages, etc. configured to elevate the upper induction
head in the entry induction station and/or the upper plate of the
first griddle module positioned in the entry induction station in
any other way.
Block S112 of the method 100 recites dispensing a first food
product onto the first lower plate in Block S112. Generally, the
system 100 executes Block S112 once the upper and lower plates of
the first griddle module in the entry induction station are opened
to receive the food product in Block S110. In one implementation,
an adjacent patty grinding system extends a patty dispenser--with
hamburger patty--between the upper and lower plates of the first
griddle module and releases the hamburger patty onto the lower
plate. The system 100 then lowers the upper plate of the first
griddle module, such as by lowering the upper induction head in the
entry induction station, to bring the upper plate in contact with
the hamburger patty.
Block S120 of the method 100 recites, during a first period of
time, driving a lower coil in the entry induction station to heat
the first lower plate and driving an upper coil in the entry
induction station to heat the first upper plate. Generally, in
Block S120, the system 100 begins to heat (e.g., cook) the first
food product now positioned between the upper and lower plates of
the first griddle module by supplying power to the upper and lower
coils in the entry induction station. In particular, when powered,
the upper and lower coils of the entry induction station
inductively couple with the upper and lower plates of the first
griddle module, respectively, thereby inducing eddy currents and
heating the upper and lower plates, which conduct heat into the top
and bottom of the food product, respectively.
During a second period of time succeeding the first period of time,
the system 100: disables the lower coil and the upper coil in the
entry induction station in Block S130; and positions the first
griddle module within an intermediate induction station in Block
S140. Generally, the system 100 disables the upper and lower coils
in the entry induction station in Block S130 in preparation to
advance the first griddle module to a next induction station in
Block S140. In particular, to prevent inductive coupling between
the upper and lower coils of the entry induction station, which may
damage the upper and lower coils, when the first griddle module is
transitioned out of the entry induction station, the system 100
disables (e.g., deactivates, cuts power to) the upper and lower
coils in Block S130 before advancing the first griddle module to a
next induction station. For example, the system 100 can initiate a
timer for a static intra-station period (e.g., ten seconds) once
the first griddle module enters the first induction station and
then deactivate the upper and lower coils of the entry induction
station in Block S130 upon expiration of the timer before advancing
the first griddle module into a next induction station.
Block S122 of the method 100 recites, during a third period of time
succeeding the first period of time, driving a lower coil in the
intermediate induction station to heat the first lower plate and
driving an upper coil in the intermediate induction station to heat
the first upper plate. Generally, in Block S122, the system 100
implements methods and techniques like Block S120 described above
to power the upper and lower coils of a second induction station
(e.g., an intermediate induction station), which inductively couple
to the upper and lower plates of the first griddle module,
respectively, to heat the first food product.
Furthermore, the system 100 can include a hub that supports both a
first griddle module and a second griddle module behind (i.e.,
lagging, succeeding) the first griddle module such that, when the
system 100 advances the first griddle module forward from the entry
induction station to the second induction station, the second
griddle module is simultaneously advanced from the exit induction
station to the entry induction station. Thus, during the third
period of time in which the system 100 powers the upper and lower
coils in the second induction station to heat the first food
product in the first griddle module in Block S122, the system 100
can repeat Block S110 to separate the upper plate from the lower
plate in the second griddle module and can repeat Block S112 to
dispense a second food product (e.g., a second hamburger patty)
onto the lower plate of the second griddle module. The system 100
can then lower the upper plate of the second griddle module onto
the second food product and simultaneously supply power to both the
upper and lower coils of the second induction station and the upper
and lower coils of the entry induction station, thereby heating the
upper and lower plates of the first and second griddle modules,
respectively, during the remainder of the third period of time.
For example, the system 100 can power the upper and lower coils of
the second induction station for a full intra-station period of ten
seconds in Block S122 while simultaneously opening the upper and
lower plates of the second griddle module, loading a second food
product into the second griddle module, and closing the second
griddle module for a subset of the intra-station period (e.g., five
seconds) in Blocks S110 and S112 and then powering the upper and
lower coils of the first induction station for the remainder of the
intra-station period in Block S120. In this example, upon
expiration of the intra-station period, the system 100 can
deactivate the upper and lower coils in the second and first
induction stations in Block S132 and simultaneously advance the
first griddle module to a third induction station (e.g., to the
exit induction station), the second griddle module to the second
induction station, and a third griddle module to the entry
induction station. The system 100 can then repeat Blocks S110 and
S112 to load a third food product into the third griddle module
while simultaneously powering the upper and lower coils in the
third and second induction stations to heat the first food product
in the first griddle module and to heat the second food product in
the second griddle module, respectively, during a second
intra-station period. The system 100 can repeat the foregoing
methods and techniques to load a food product onto a griddle module
as each griddle module enters the entry induction station, to
advance each griddle module through the set of induction stations
to the exit induction station, and to intermittently power the
upper and lower coils of the induction stations to heat food
products arranged in adjacent griddle modules.
Block S160 of the method 100 recites, at a sixth time succeeding
the fifth period of time, separating the first upper plate from the
first lower plate of the first griddle module positioned within the
exit induction station; and Block S162 of the method 100 recites
removing the first food product from the first lower plate.
Generally, in Blocks S160 and S162, the system 100 implements
methods and techniques similar to those of Blocks S110 and S112 to
open the first griddle module--now positioned in the exit induction
station--and to remove the first food product--now fully heated or
cooked--from the first griddle module. In one implementation, the
exit induction station includes an upper induction head configured
to house the upper coil, the system 100 includes an exit elevation
actuator--like the entry elevation actuator--configured to elevate
the upper induction head of the exit induction station, and the
first griddle module includes a skid 116 that engages a feature on
the upper induction head of the exit induction station to
vertically couple the first griddle to the upper induction head
when the first griddle module is positioned in the exit induction
station. The system 100 can also include a retrieval system
configured to remove a food product from a griddle module, such as
in the form of a paddle and a retrieval actuator that draws the
paddle across the lower plate of a griddle module positioned in the
exit induction station to collect a food product from the griddle
module, as described below.
For example, once the first griddle module is positioned in the
exit induction station and once the first food product has reached
a sufficient temperature, has been exposed to sufficient heat flux,
has cooked for a target period of time, or has cooked for at least
a threshold period of time through the set of induction stations,
the system 100 can: deactivate the upper and lower coils in the
exit induction station; trigger the exit elevation actuator to
raise the upper induction head of the exit induction station,
thereby raising the upper plate of the first griddle module; and
then trigger the retrieval actuator to insert the paddle between
the first food product and the lower plate. The retrieval actuator
can then retract the paddle from the first griddle module and draw
the paddle across a ledge--arranged over a dispense position--to
release the first food product from the paddle onto a hamburger bun
(or into a box, onto a salad, etc.) below in Block S162. The system
100 can repeat this process for each griddle module that enters the
exit induction station.
6. Griddle Module and Hub
As shown in FIGS. 1 and 4, the system 100 includes a first griddle
module 110, which includes a lower plate 111 configured to receive
a first food product and an upper plate 112 arranged over the lower
plate 111 and configured to contact the first food product.
Generally, the system 100 includes one or more like griddle modules
110, wherein each griddle module 110 includes an upper plate 112
and a lower plate 111 configured to inductively couple to upper and
lower induction coils, respectively, in an adjacent induction
station. When the upper coil of an induction station outputs an
alternating magnetic field that penetrates the upper plate 112 of
an adjacent griddle module 110 (i.e., a griddle module 110 arranged
in the induction station), eddy currents form in the upper plate
112, which heat the plate via Joule heating; when similarly
powered, the lower coil in the induction station can similarly
induce eddy currents in the lower plate 111 of the griddle module
110 to heat the lower plate 111. When positioned within an
induction station and thus heated via induction heating, a griddle
module 110 can thus form a double-sided (or "clamshell") inductive
griddle configured to heat both the top and bottom surfaces of a
food product.
In one implementation, the upper plate 112 of a griddle module 110
includes a ferrous (e.g., a steel, a cast iron, ferromagnetic,
and/or ferrimagnetic) substrate defining a planar cooking surface
coated with a "non-stick" (e.g., low-friction) material, such as a
ceramic (e.g., alumina), Polytetrafluoroethylene (PTFE), or
perfluorooctanoic acid (PFOA). The upper plate 112 can also include
one or more thermal layers between the ferrous substrate and the
non-stick coating. For example, the upper plate 112 can include: a
ferrous substrate configured to Joule heat in the presence of an
oscillating magnetic field output by an upper coil of an adjacent
induction station; a copper layer bonded (e.g., brazed, diffusion
bonded) over the ferrous substrate and configured to distribute
heat across the ferrous substrate; an aluminum layer bonded over
the copper layer to define a planar food-safe cook surface; and a
non-stick coating applied over the aluminum layer.
In the foregoing implementation, the upper plate 112 can be
symmetric about its Y-axis and can define a second planar cooking
surface opposite and parallel to the (first) planar cooking
surface, wherein the second cooking surface is similarly coated
with a non-stick material. Thus, when the non-stick performance of
the non-stick coating on the first cook surface is sufficiently
degraded, the upper plate 112 can be flipped on the hub--such as
manually by an operator following a cleaning cycle--to expose the
"fresh" non-stick coating on the second cooking surface. Similarly,
the upper plate 112 can be systematically flipped about its Y-axis
between operating periods of the automated foodstuff assembly
apparatus 200 in order to yield substantially uniform degradation
of the non-stick coating over time and to extend the useful life of
the upper plate 112. In the example above in which the upper plate
112 includes one or more thermal layers over a ferrous substrate,
the upper plate 112 can similarly include copper and aluminum
layers across the opposite side of the ferrous substrate such that
the ferrous substrate defines a ferrous core that heats in the
presence of an oscillating magnetic field, and the copper layers
can disperse this heat across both sides of the ferrous core.
A griddle module 110 in the system 100 can include a lower plate
111 of the same or similar material(s) and geometry. For example, a
griddle module 110 can include identical (e.g., interchangeable)
upper and lower plates 112, 111.
The system 100 also includes a hub: configured to support the lower
plate 111 and the upper plate 112 of the first griddle module 110
between the barrier and upper coils of the induction stations with
the lower plate 111 offset above the barrier and the upper plate
112 offset below upper coils of the induction stations; and
configured to sequentially position the first griddle module 110
through the set of induction stations from the entry induction
station to the exit induction station 123. Generally, the hub
function to support the upper and lower plates 112, 111 of one or
more griddle modules 110 between upper and lower induction coils of
the induction stations throughout operation of the system 100.
In one implementation, the upper plate 112 includes an upper plate
receptacle 113 configured to locate the upper plate 112 on the hub
between the upper and lower induction coils of the induction
stations, as shown in FIGS. 3 and 5. In one implementation, an
upper plate receptacle 113 defines a pair of beams extending
outwardly from the hub, and a corresponding upper plate 112 defines
a circular cast iron platter of uniform thickness fastened to the
beams of the upper plate receptacle 113 with one or more threaded
fasteners.
In another implementation, the upper plate 112 defines a circular
plate with a tongue 117 extending from an edge of the upper plate
112. In this implementation, the distal end of the tongue defines a
chamfered lead-in on each broad side and a recess behind each
chamfered lead-in, as shown in FIG. 3. The upper plate receptacle
113 defines a receiver 116 that accepts the tongue of the upper
plate 112 and a sprung follower 118 that engages the recess on the
tongue of the upper plate 112 to constrain the upper plate 112 in
the receiver. In this implementation, to install an upper plate 112
in an upper plate receptacle 113, an operator can manually insert
the tongue of the upper plate 112 into the receiver; the chamfered
lead-in of the tongue can retract the follower as the tongue is
inserted into the receiver; and the follower can extend into and
engage the recess in the tongue to constrain the upper plate 112 in
the receiver once the upper plate 112 is fully inserted into the
receiver, thereby locking the upper plate 112 to the upper plate
receptacle 113. The operator can then manually draw the upper plate
112 laterally away from the upper plate receptacle 113 to release
the follower from the recess and to remove the upper plate 112 from
the upper plate receptacle 113, such as to clean the system 100.
(Alternatively, the upper plate receptacle 113 can include a pin,
magnet, or other element or feature that engages and retains the
upper plate.) The upper plate receptacle 113 can also include one
or more guide rails that laterally constrain the upper plate.
In one implementation, the system 100 includes: a conveyor system
including the hub and a hub actuator 141 that rotates the hub
through a sequence of positions corresponding to induction
stations; and a set of like griddle modules 110, wherein the upper
plate receptacle 113 of each griddle module 110 is configured to
transiently install on the hub. For example, the hub can include a
set of vertical posts 143, and each upper plate receptacle 113 can
include a linear slide configured to engage and to translate
linearly along a corresponding post 143 when lifted by an upper
induction head 126 in the entry and exit induction stations 121,
123 in Blocks S110 and S160 (or vice versa), as shown in FIGS. 5
and 7. In this example, the hub can include a lower plate 111
receptacle configured to transiently receive the lower plate 111,
like the upper plate receptacle 113, but intransiently coupled to
the hub, and the upper plate receptacle 113 can be configured to
slide vertically along a post 143 of the hub to enable the system
100 to separate the upper plate 112 from the lower plate 111 in
Blocks S110 and S160 in preparation to receive and to release a
food product, respectively. An upper plate receptacle 113 and upper
plate 112 assembly can thus be fully removable from the post 143 by
manually drawing the upper plate receptacle 113 vertically upward
past the post 143, and the upper plate 112 can be separated from
the lower plate 111 receptacle by drawing the lower plate 111
laterally outward, as described above, such as for cleaning.
Alternatively, a griddle module 110 can similarly include a lower
plate 111 receptacle: that transiently engages the hub, such as
over a post 143 extending from the hub and shared with a
corresponding upper plate receptacle 113; that supports the lower
plate 111; and that can be removed from the hub with the upper
plate receptacle 113, such as for cleaning or other servicing.
In the foregoing implementation in which the hub includes one
vertical post 143 (or multiple vertical posts) per griddle module
110 and in which a griddle module 110 is configured to slide
vertically along its corresponding post 143 on the hub, an upper
plate receptacle 113 in a griddle module 110 can further include a
skid 116 configured to engage an upper induction head 126 of an
adjacent induction station (i.e., the entry induction station, the
exit induction station 123) and to loft the upper plate receptacle
113 along its post 143 when the upper induction head 126 is
retracted, thereby separating the upper plate 112 from its paired
lower plate 111 to receive a new food product at the entry
induction station in Blocks S110 and S112 or to release a cooked
food product from the griddle module 110 at the exit induction
station 123 in Blocks S160 and S162. For example, the entry
induction station can include an upper induction head 126 that
defines a T-slot concentric with the axis of rotation of the hub,
and a griddle module 110 can include a skid 116 defining a T-head
configured to enter the T-slot as the griddle module 110 is
advanced into the entry induction station; the upper induction head
126 can thus draw the T-head and the upper plate receptacle 113
upward when elevated by the elevation module in the entry induction
station in Block S110. The exit induction can define a similar
geometry configured to elevate the griddle module 110 in Block
S160.
The hub can thus support and locate each lower plate 111 of a
griddle module 110 in vertical alignment with its corresponding
upper plate 112 and offset vertically above the barrier of the
base. In particular, the hub can support lower plates 111 of the
griddle modules 110 out of mechanical contact with the barrier of
the base in order to limit conduction of heat from the lower plates
111 into the barrier and into the lower coils. For example, the hub
can support lower plates 111 of the griddle modules 110 at a fixed
distance above the barrier and offset above lower coils arranged in
the base by a distance corresponding to a peak inductive coupling
distance for the lower coils.
7. Induction Stations
As shown in FIGS. 1 and 4, an induction station in the system
includes a set of induction stations 120 including an entry
induction station 121 and an exit induction station 123, wherein
each induction station in the set of induction stations 120
includes: a lower coil configured to inductively couple to the
lower plate when the first griddle module is arranged in the
induction station; and an upper coil configured to inductively
couple to the upper plate when the first griddle module is arranged
in the induction station. Generally, an induction station in the
system 100 includes an upper coil and a lower coil that inductively
couple to adjacent upper and lower plates of a griddle module,
respectively, when the griddle module is positioned within the
induction station.
In one implementation, each induction station can also include one
power controller and an electronic oscillator that cooperate to
pass a high-frequency alternating current through one or both of
the upper and lower coils. When thus powered, the upper coil of the
induction station can output a high-frequency alternating magnetic
field that penetrates the upper plate in an adjacent griddle
module, which thus induces eddy currents in the upper plate. These
eddy currents thus formed in the upper plate can then induce
heating within the plate, such as by Joule heating and/or by
magnetic hysteresis losses. For example, the system 100 can include
one power controller and one electronic oscillator per each of the
upper and lower coils in an induction station, one power controller
and one electronic oscillator per pair of upper and lower coils in
an induction station, or any other number or combination of power
controllers and electronic oscillators.
An induction station can also include an upper induction head 126
that houses the upper coil of the induction station, as described
above. In one implementation, an upper induction head 126 can
include a housing hinged to and supported by the base and defining
an aperture facing the base. The upper coil of the induction
station can be arranged within the housing and can be configured to
output an alternating magnetic field through the aperture.
Furthermore, the aperture can be closed by a window of a
substantially magnetically-transparent material (e.g., window of a
material exhibiting relatively minimal ferromagnetism and
relatively minimal ferrimagnetism) that physically seals the upper
coil within the housing. For example, the window can include a
borosilicate transparent glass plate exhibiting a relatively low
coefficient of thermal expansion and supported by a flexure
extending from the housing. The upper induction head 126 can also
include a heat barrier between the upper coil and the non-magnetic
window to reduce heat transmission from outside the housing into
the upper coil, and the upper induction head 126 can be coupled to
a remote air supply that forces air through the upper induction
head 126 to actively cool the upper coil.
The upper coil of the entry induction station 121 can be housed in
a discrete entry upper induction head 126, and the upper coil of
the exit induction station 123 can be similarly housed in a
discrete exit upper induction head 126. Upper coils in two or more
intermediate induction stations 122 can be ganged into a single
housing to form a single upper induction head 126 that spans the
multiple intermediate induction stations 122, as shown in FIG. 2.
For example, the induction station can include a single housing
containing three upper coils for each of three intermediate
induction stations 122. Furthermore, the system 100 can support the
ganged upper induction head 126 in a static position offset above
the base and spanning the intermediate induction stations 122.
Furthermore, the upper induction head 126 of the entry induction
station 121 can be coupled to an elevation actuator 127 configured
to raise and lower the upper entry induction head to thus raise and
lower the upper plate of a griddle module in entry induction
station 121 in Block S110; the upper induction head 126 of the exit
induction station 123 can be similarly coupled to an elevation
actuator 127 configured to raise and lower the upper induction head
126 in Block S160. For example, an upper induction head 126 can be
supported over the base by a pair of parallel linkages coupled to a
linear or rotatory actuator, as shown in FIG. 1, configured to lift
the induction head (and an adjacent upper plate) by a relatively
small distance (e.g., 2.0'') to accept a new food product in Blocks
S110 and S112 or to release a cooked food product in Blocks S160
and S162. Alternatively, like the upper plate receptacle and hub,
an upper induction head 126 can slide vertically along a post 143
extending from the base, and a linear actuator, rotatory actuator,
and/or linkage system can position the upper induction head 126
along the post 143 in order to separate the upper plate from the
lower plate of an adjacent griddle module in Block S110 or Block
S160 and/or to set an offset distance or compression height between
the upper and lower plates in the adjacent griddle module in Block
S182 described below. Individual or ganged upper induction heads
126 in the intermediate induction station(s) 122 can be similarly
supported off of the base and can be similarly adjusted vertically
to set offset distances or compression heights between the upper
and lower plates in adjacent griddle modules in Block S182.
The lower induction coil can be arranged in the base, as described
below.
In one implementation, the system 100 includes a number of
induction stations equal to its number of griddle modules. In this
implementation, the system 100 can load raw food products into
griddle modules in the entry induction station 121 in Block S112
and remove cooked food products from griddle modules in the exit
induction station 123 in Block S162. For example, the system 100
can include an entry induction station 121, three intermediate
induction stations 122, and one exit induction station 123.
Alternatively, the system 100 can include one fewer induction
station than griddle modules. For example, the system 100 can
remove a cooked food product and then reload the griddle module
with a raw food product in Blocks S162 and S112, respectively, when
the griddle module is positioned in a load/unload position between
an entry induction station 121 and an exit induction station 123.
In another example, the system 100 can load raw food products into
griddle modules in a load position adjacent the entry induction
station 121 and unload cooked food products from griddle modules in
an unload position adjacent the exit induction station 123 (e.g.,
between the exit induction station 123 and the load position).
However, the system 100 can include any other number of griddle
modules and any other number of induction stations in any other
suitable configuration. In yet another example, the system 100 can
load and unload food products from griddle modules in a single
position, such as from the entry induction station 121 (which can
thus be physically coextensive with the exit induction station
123).
Furthermore, the system 100 can include a number of griddle modules
approximately equivalent to a time required to fully heat (or cook)
a food product to done divided by a target rate of done food
products output by the system 100. For example, for a hamburger
patty of mass necessitating up to 50 seconds to cook to well-done
and for a target output rate of one cooked hamburger patty per
ten-second interval, the system 100 can include five griddle
modules and five induction stations, and the system 100 can
implement a static intra-station period of twelve seconds,
including ten seconds of active heating and two seconds to advance
the griddle modules to a next position per intra-station period. In
this example, a sequence of five intra-station periods can thus
define one cook cycle for one food product.
8. Base
As shown in FIGS. 1 and 4, the system 100 includes a base 130:
including a barrier; supporting a lower coil of an induction
station on a first side of the barrier; and supporting an upper
coil of an induction station on a second side of the barrier
opposite and aligned with the lower coil of the induction station
for each induction station in the set of induction stations.
Generally, the base 130 houses the lower coils of the induction
stations, houses related power controllers and electronic
oscillators (e.g., "generator boards"), houses components of the
conveyor system, and supports the upper induction heads 126, as
described above.
In one implementation, the base 130 defines an enclosure with an
aperture facing the upper induction heads 126, and the aperture is
enclosed by a barrier, such as a borosilicate glass plate or a
barrier of any other suitable material exhibiting low
ferromagnetism and/or low ferrimagnetism. The base 130 can house
the lower coils and the generator boards inside the enclosure with
the lower coils adjacent the barrier and configured to output
alternating magnetic fields through the barrier to lower plates of
adjacent griddle modules.
9. Conveyor System
As shown in FIG. 1, the conveyor system includes a hub that
supports upper and lower plates of griddle modules between the
barrier and the upper induction heads of the induction stations.
The conveyor system also includes a hub actuator 141 arranged
within the base and configured to sequentially index a griddle
module from the entry induction station to an intermediate
induction station in Block S140 and from the intermediate induction
station to the exit induction station in Block S142. Generally, the
base houses multiple lower coils and supports multiple upper
induction heads, each including an upper coil, and the conveyor
system positions griddle modules vertically between induction
stations and indexed griddle modules through the set of induction
stations as raw food products are sequentially loaded into the
griddle modules in the entry induction station, cooked throughout
the set of induction stations, and then removed at the exit
induction station, such as for assembly with other ingredients into
a hamburger.
The hub actuator 141 is arranged within (or is coupled to) the base
and supports the hub 140 above the barrier. In one implementation
in which the griddle modules and induction stations are patterned
radially about the axis of the hub 140, the hub actuator 141
includes an electric motor (e.g., servo motor, stepper motor) and a
gearbox, wherein an output shaft of the gearbox is keyed and
extends through a bore proximal the center of the barrier of the
base to engage and support the hub 140 above. In this
implementation, the conveyor system can include a thrust bearing
that vertically supports the hub 140 over the barrier, and the
conveyor system can also include a seal--arranged about the thrust
bearing--that resists ingress of debris (e.g., water, fat, grease)
past the barrier and into the base. In this implementation, the
system 100 can include a position sensor that outputs a signal
corresponding to the angular position of the motor, of the gearbox,
of the output shaft, of the hub 140, or of a griddle module, and
the system 100 can implement closed-loop feedback techniques to
position griddle modules in alignment with the induction stations
based on outputs of the position sensor. For example, the conveyor
system can include an optical encoder wheel coupled to a keyed
shaft and an optical encoder reader adjacent the wheel. The
conveyor system can additionally or alternatively include an
optical sensor, limit switches, and/or other sensors arranged in a
base and/or on an upper induction head and outputting signals
corresponding to the angular position of the hub 140; and the
system 100 can control the hub actuator 141 to reposition the hub
140 during operation of the system 100 accordingly.
Alternatively, the conveyor system can include gearbox including a
Geneva mechanism. In this implementation, the indexing wheel of the
Geneva mechanism can be coupled to the hub 140, and the conveyor
system can run the hub actuator 141 at a substantially constant
speed intermittently rotating the indexing wheel through a sequence
of index positions corresponding to the induction stations. In this
implementation, the system 100 can set a speed of the hub actuator
141 based on a target intra-station period and an effective gear
reduction of the Geneva mechanism, and the conveyor system can
implement closed loop controls to maintain the output speed of the
hub actuator 141 accordingly.
In Blocks S130 and S132, the system 100 can also deactivate (e.g.,
cut power to) the upper and lower coils of the induction stations
prior to advancing the hub 140--and therefore the griddle
modules--to a next angular position in Blocks S140 and S142 in
order to prevent the upper coil of an induction module from
inductively coupling to the lower coil of the induction module,
which may damage a generator board connected to the induction
module, as described above.
In one configuration, the hub 140 supports both the upper and lower
plates of each griddle module in a radial pattern, and the hub
actuator 141 rotates the hub 140 to advance griddle
modules--cantilevered off of the hub 140--along an arcuate path
through each induction station arranged in a circular pattern about
the base, as shown in FIG. 2. In one implementation, the system 100
includes multiple (e.g., five) induction stations arranged in a
radial pattern about a center axis of the base; the hub 140 is
arranged over an axial center of the barrier and supports upper and
lower plates of multiple (e.g., five) griddle modules in a
corresponding radial pattern; and the hub actuator 141 rotates the
hub 140 through a sequence of angular positions radially offset by
72.degree. to sequentially index the griddle modules through the
induction stations. In this configuration, the hub 140 can include
multiple (e.g., five) vertical posts, each engaging an upper plate
receptacle 113 of one griddle module such that each upper plate
receptacle 113 can slide linearly (e.g., vertically) along its
corresponding post 143, as described above. For example, the system
100 can raise an upper induction head at the entry induction
station to lift an upper plate of a griddle module positioned in
the entry induction station, and the upper plate receptacle 113 can
slide along its corresponding post 143 in the hub 140 to follow the
upper induction head; the system 100 can then lower the upper
induction head to release the upper plate toward its lower plate
once a new food product has been dispensed onto the lower plate and
before (or as) the upper and lower coils of the entry induction
station are activated to heat the upper and lower plates,
respectively. Upon the conclusion of each intra-station period, the
hub actuator 141 rotates the hub 140 forward, thereby advancing
each griddle module into a subsequent induction station. When a
griddle module enters the exit induction station and a heating
period at the exit induction station is completed (e.g., over a
portion of the intra-station period), the system 100 elevates the
upper induction head of the exit induction station, which draws the
upper plate receptacle 113 up its post 143 on the hub 140 to reveal
a cooked food product, and the system 100 triggers the retrieval
system to collect the food product from the griddle module.
Alternatively, the system 100 can include multiple induction
stations arranged in a linear array. In this configuration, the hub
140 can support the upper and lower plates of the griddle modules
in a similar linear array, and the hub actuator 141 can linearly
advance the griddle modules along the linear array of induction
stations. For example, the system 100 can include: a linear array
of five induction stations, including an entry induction station,
three intermediate induction stations 122, and an exit induction
station arranged in a line; ten (or more) griddle modules; a hub
including a continuous linear conveyor configured to advance a
griddle module from the entry induction station to the exit
induction station and to return the griddle module to the entry
induction station when driven in a single direction by the hub
actuator 141.
However, the system 100 can include any other number of induction
stations and griddle modules arranged in any other pattern, array
or configuration, and the conveyor system can transition griddle
modules through each induction station throughout operation.
11. Insertion System
As shown in FIGS. 6 and 7, one variation of the system 100 includes
an insertion system 150 configured to place a food product onto the
lower plate of a griddle module positioned in the entry induction
station. Generally, the insertion system 150 functions to dispense
a food product into a griddle module in the entry induction station
in preparation to heat or cook the food product.
In one implementation, the system 100 interfaces with a patty
grinding system that grinds chunks of meat, meters discrete masses
or volumes of ground meat, and presses meat patties; and the
insertion system 150 includes a platen, a pusher, and an actuator
that retracts the pusher and the platen into the grinding system to
collect a patty, advances the platen into a dispense position
between the upper and lower plates of a griddle module in the entry
induction station, and then advances the pusher--relative to the
platen--to propel the patty off of the platen and onto the lower
plate of the griddle module. However, the insertion system 150 can
be of any other format and can function in any other way to
transfer a food product into a griddle module in the entry
induction station in Block S112. In another implementation, the
insertion system 150 includes a cup, a piston running within the
cup, a boom supporting the cup on one end, and an actuator system.
In this implementation, the actuator system positions the cup
inside the grinder system, the grinder system loads a food product
(e.g., ground meat) into the cup, and the actuator system then
advances the cup outside of the grinder system and into the griddle
module in the entry induction station, inverts the cup, and drives
the piston forward to push the food product out of the cup and onto
the lower plate of the griddle module before resetting the piston
and cup and returning the cup to the grinder system.
12. Retrieval System
As shown in FIG. 2, the retrieval system 150 includes a paddle 161
and a retrieval actuator 162 that selectively advances the paddle
161 across a lower plate of a griddle module in the exit induction
station to retrieve a patty from the lower plate. Generally, the
retrieval system 150 includes an arm, a paddle 161, and a retrieval
actuator 162 that cooperate to collect a heated or cooked food
product from a griddle module in the exit induction station.
In one implementation, the retrieval actuator 162 includes an arm,
a paddle 161 cantilevered from the distal end of the arm and
drooping slightly downward (e.g., at an angle of 2.degree. from the
top surface of the lower plate of an adjacent griddle module) in an
initial position, and a retrieval actuator 162 configured to
position the arm between a collect position within the exit
induction station and a nearby dispense position. In this
implementation, to remove a patty from a griddle module at the exit
induction station in Block S162, the system 100 triggers an exit
elevation actuator 127 to raise the upper induction head of the
exit induction module, which catches the skid 116 extending from
the upper plate receptacle 113 of the adjacent griddle module and
separates the upper plate from its corresponding lower plate. The
system 100 then triggers the retrieval actuator 162 to swing or
extend the arm toward the exit induction station. As the paddle 161
approaches the griddle module, retrieval actuator 162 drives the
leading edge of the paddle 161 downward and into contact with the
top surface of the lower plate, thereby deflecting the tip of the
paddle 161 upward. The retrieval actuator 162 then drives the
paddle 161 toward a backstop on or adjacent the lower plate (as
described below), which constrains the food product as the paddle
161 is inserted between the patty and the lower plate. For example,
the paddle 161 can define a tip initially declined downward at a
first angle below horizontal, and the retrieval actuator 162 can
drive the tip of the paddle 161 downward against the top surface of
the lower plate in the exit induction station until the tip of the
paddle 161 is declined downward at a second angle less than the
first angle below horizontal, thereby compressing the tip of the
paddle 161 against the top of the lower plate to enable the tip of
the paddle 161 to scrape the food product from the lower plate
substantially without piercing the food product as the retrieval
actuator 162 pivots or extends the paddle 161 laterally (e.g.,
horizontally) to collect the first food product from the lower
plate onto the paddle 161 in Block S162. The retrieval actuator 162
then raises the arm--which raises the paddle 161 and the food
product off of the lower plate--and advances the paddle 161 into
the dispense position over an adjacent conveyor supporting a box, a
plate, or a bun, etc. below. In this implementation, the retrieval
system 150 also includes a ledge 163 arranged over the conveyor,
and the retrieval actuator 162 sweeps the paddle 161 past the ledge
163, which constrains the food product as the retrieval actuator
162 draws the paddle 161 past the ledge 163, thereby displacing the
food product from the paddle 161 and onto a hamburger bun (or into
a box, onto a plate, onto a salad, etc.) supported on the conveyor
below.
In the foregoing implementation, the ledge 163 can also include an
integrated scraper, squeegee, or other like structure configured to
wipe or scrape waste--such as grease or loose particles from the
food product--from the paddle 161 as the retrieval actuator 162
draws the paddle 161 past the ledge 163. For example, the retrieval
actuator 162 can pivot the paddle 161 in a first direction--from
the ledge 163 toward the exit induction station--with the tip of
the paddle 161 leading to collect a food product from a griddle
module in the exit induction station, and the retrieval actuator
162 can then pivot the paddle 161 in an opposite direction--back
toward the ledge 163--with the tip of the paddle 161 trailing to
draw the paddle 161 past the ledge 163 and integrated scraper,
thereby driving the food product and food waste collected on the
paddle 161 off of the paddle 161 and toward the conveyor below.
Furthermore, in this implementation, the ledge 163 can include two
opposing scrapers, squeegees, or other like structures, and the
retrieval actuator 162 can draw the paddle 161 through a void
between the opposing structures to clean food waste from both sides
of the paddle 161. However, the ledge 163 can include any other one
or more features configured to dispel food waste from the paddle
161, and the retrieval actuator 162 can manipulate the paddle 161
in any other way and between any other positions to collect a food
product from the exit induction station and to dispense the food
product onto a hamburger bun, box, or plate, etc.
As described above, a griddle module can also include a backstop
configured to prevent a food product arranged on the lower plate
from falling off the lower plate and onto the base, such as when
the retrieval system 150 retrieves a heated or cooked food product
from the lower plate in the exit induction station. For example,
for the retrieval system 150 that extends a paddle 161
longitudinally toward the hub to collect a food product from
griddle modules in the exit induction station, a lower plate (and
the upper plate) in a griddle module can include a backstop
extending vertically from its cook surface along a section of the
perimeter of the lower plate facing the hub and configured to
function as a backstop to prevent a food product from shifting
toward the hub and off the lower plate when the retrieval system
150 is actuated to collect the food product in Block S162.
Similarly, for the retrieval system 150 that extends a paddle 161
laterally across a lower plate to collect a food product from the
lower plate, the lower plate (and the corresponding upper plate)
can include a backstop extending vertically from its cook surface
along one side of the perimeter of the lower plate opposite the
approach direction of the retrieval system 150 to prevent a food
product from shifting away from the tip of the paddle 161 as the
paddle 161 is driven between the food product and lower plate in
Block S162. Alternatively, the hub can include a backstop extending
toward the perimeter of the lower plate between the upper and lower
plates of the griddle module and can be fixed in position relative
to the griddle module. Yet alternatively, the system 100 can
include static backstops fixedly (e.g., intransiently) supported by
the base adjacent each induction station. However, the system 100
can include one or more backstops of any other form and mounted to
any other one or more elements within the system 100.
13. Waste Management
As shown in FIG. 5, one variation of the system 100 includes a
waste management system 170 that collects debris (e.g., water, fat,
grease) released by food products heated or cooked in the system
100 during operation.
In one implementation in which the base defines a circular or
polygonal cross-section and supports induction stations in a radial
array, the waste management system 170 includes a trough 134
arranged about a perimeter of the base and defining a valley below
the barrier. In this implementation, the waste management system
170 can also include a wiper 142 mounted to the hub (or to a lower
plate or lower plate receptacle installed on the hub), extending
across a surface of the barrier, and configured to drive food waste
deposited onto the barrier toward the trough during rotation of the
hub. In particular, the wiper 142 can scrape debris from the
surface of the barrier and drive this debris into the trough as the
hub rotates. For example, the wiper 142 can include a silicone (or
PTFE or other rubber or plastic) wiper blade defining a curvilinear
profile extending from proximal the center of the hub, past the end
of the barrier, and into the trough. In this example, the wiper 142
can also define a curvilinear profile spiraling outward from the
center of the hub opposite the direction of rotation of the hub in
order to drive waste collecting on the barrier outwardly toward the
trough. As the hub actuator rotates the hub, the wiper 142 can thus
wipe fats, water, and other waste collecting on the barrier toward
the trough, such as to maintain a relatively clean barrier, to
manage waste, and/or to maintain substantially consistent inductive
coupling between lower coils and adjacent lower plates by removing
waste that may otherwise absorb the magnetic fields' output by the
lower coils.
In this implementation, the trough can extend along an edge of the
barrier and can define a drain, and the waste management system 170
can also include: a collection canister 173; a conduit 172
extending from a base of the trough to the collection canister 173;
and a heating element 171 arranged on the conduit 172, as shown in
FIG. 5. The collection canister 173 can be arranged in the base
below the trough, and the heating element 171 can maintain the
temperature of the conduit 172 (and/or the trough and/or the
collection canister 173) above a common flow temperature of waste
released from food products loaded into the system 100 (e.g., above
160.degree. F., a common flow temperature of meat fat) in order to
prevent obstruction of the conduit 172 by cooled and hardened
waste. The waste management system 170 can additionally or
alternatively include a discrete heating element thermally coupled
to the trough and configured to maintain the trough above such a
threshold temperature, or the trough can be thermally coupled to
the barrier, which can maintain the temperature of the trough above
the threshold temperature during operation; the waste management
system 170 can similarly include a discrete heating element
thermally coupled to the collection canister 173 and configured to
maintain the collection canister 173 above such a threshold
temperature. However, the waste management system 170 can maintain
the trough, the drainage line, and/or the collection canister 173
at an elevated temperature in any other way in order to limit
coagulation and collection of fats and other debris in the trough,
in the drainage line, and along walls of the collection canister
173.
In this implementation, the waste management system 170 can include
additional wipers extending across the barrier--such as arranged in
a radial pattern about the hub--and configured to drive debris from
the surface of the barrier into the trough. Each wiper 142 can also
extend from the surface of the barrier into the trough and can thus
drive waste in the trough forward and toward the drain as the hub
is rotated, thereby limiting collection of debris in the
trough.
14. Plate Scraper
One variation of the system 100 further includes a plate scraper
configured to scrape debris from the upper plate and/or the lower
plate of a griddle module as the system 100 advances the griddle
module from the exit induction station back to the entry induction
station in preparation to receive a next food product. Generally,
the plate scraper functions to scrape grease, water, grizzle, meat
particles, etc. from the upper plate and/or the lower plate in a
griddle module as the conveyor system advances the griddle module
from the exit induction station back to the entry induction station
and in preparation to receive a new food product in Block S112.
In one implementation, the plate scraper is fixedly mounted to the
base between the exit induction station and the entry induction
station and includes an upper silicone (or PTFE or other rubber or
plastic) wiper blade (e.g., like the wiper described above) and a
lower silicone (or PTFE or other rubber or plastic) wiper blade
sprung outwardly and configured to scrape the lower surface of the
upper plate and the upper surface of the lower plate, respectively,
of a griddle module as the hub advances the griddle module from the
exit induction station to the entry induction station.
Alternatively, the plate scraper can include a static bristle brush
(formed from stainless steel, rubber, or a polymeric material, for
example) or an active (e.g., oscillating, rotating) bristle brush
(formed from stainless steel, rubber, or a polymeric material, for
example) or that scrapes debris from the upper and lower plates as
the griddle module is advanced past the plate scraper. The plate
scraper can thus passively or actively abrade the cooking surfaces
of the upper and lower plates of a griddle module as the griddle
module transitions from the exit induction station to the entry
induction station, thereby removing waste and reducing a surface
contact area of the cooking surfaces to reduce opportunity for a
new food product dispensed into the griddle module in Block S112
from sticking to the upper and lower plates of the griddle
module.
The system 100 can also include a grease module arranged between
the exit and entry induction stations, such as interposed between
the plate scraper and the entry induction station. For example, the
grease module can include one or more nozzles--arranged between the
exit and entry induction stations--that spray water, butter, and/or
cooking oil, etc. onto the opposing cooking surfaces of the upper
and lower plates of a griddle module as the conveyor system
advances the griddle module from the exit induction station to the
entry induction stations, such as immediately after the upper and
lower plates are scraped by the plate scraper.
15. Temperature Sensing
As shown in FIGS. 3, 4, 6, and 8, one variation of the griddle
module includes a temperature sensor 114 that outputs a signal
corresponding to the temperature of an upper and/or lower plate in
the griddle module, and the system 100 samples the temperature
sensor 114 during operation to track the temperature of the upper
and/or lower plates and adjusts power outputs of the upper and
lower coils of the induction stations accordingly. For example, the
system 100 (e.g., the controller 180) can implement closed-loop
feedback techniques to modulate the power outputs of the upper and
lower coils of the induction stations to achieve a single target
temperature of the upper and lower plates of a griddle module, to
achieve a sequence of target temperatures in the upper and lower
plates of the griddle module, to achieve a target heat flux into a
food product arranged in the griddle module, etc. during a cook
cycle based on outputs of the temperature sensor(s) 114 and a
doneness value specified for the food product. Alternatively, the
system 100 can adjust an intra-station period at an induction
station based on outputs of the temperature sensors 114 in order to
achieve a doneness value specified for a corresponding food
product.
In one implementation, a griddle module includes a contact-based
temperature sensor 114, such as a thermocouple, thermistor,
resistance temperature detectors (RTDs), or silicon bandgap
temperature sensor in contact with an upper plate in the griddle
module. In one example implementation, the upper plate of the
griddle module includes: a channel on the back side of the upper
plate--opposite a cooking surface--and running from the tongue of
the plate, along the back side of the upper plate, to the axial
center of the upper plate; a temperature sensor 114 arranged in the
channel proximal the axial center of the plate; a sensor plug 119
(or sensor receptacle) arranged on the tongue; electrical leads
arranged within the channel and electrically coupled to the
temperature sensor 114 and to the sensor plug (or sensor
receptacle); potting material arranged over the temperature sensor
114 and the electrical leads within the channel; and a closing
insert arranged within the channel and enclosing the temperature
sensor 114, electrical leads, and potting material within the
channel, as shown in FIG. 3. In this example implementation, the
closing insert can be: dovetailed and press-fit into the channel
that is similarly dovetailed; welded or brazed into the channel;
mechanically fastened in the channel; or constrained within the
channel in any other suitable way.
In the foregoing example, the hub can include an upper sensor lead
receptacle 149, such as integrated into the upper plate receptacle
(shown in FIG. 3) or physically distinct from the upper plate
receptacle 113, and the sensor plug extending from the temperature
sensor 114 in the upper plate can mate with the upper sensor lead
receptacle in the upper plate receptacle of the hub when the upper
plate is installed in the upper plate receptacle or when the upper
plate and upper plate receptacle assembly are installed on the hub,
as shown in FIG. 3. Therefore, the upper plate can include an
integrated temperature sensor 114 proximal an axial center of the
upper plate and a sensor lead extending laterally from the
temperature sensor 114, and the sensor lead can transiently couple
to the upper sensor lead receptacle in the hub during operation of
the system 100 and can be removed from the sensor lead receptacle
with the upper plate, such as for cleaning. The lower plate of the
griddle module can similarly include an integrated temperature
sensor 114 proximal an axial center of the lower plate and a sensor
lead extending laterally from the temperature sensor 114, and this
sensor lead can similarly couple to and decouple from a lower
sensor lead receptacle in the hub.
In another example, an upper plate in a griddle module defines a
blind bore extending laterally from an edge of the plate (e.g.,
from the tongue) toward the axial center of the upper plate. In
this example, the griddle module includes a beam extending from the
upper plate receptacle 113 (or from the hub) and terminating in a
temperature sensor 114. In this example, the beam can be inserted
into the blind bore and can support the temperature sensor 114
inside of and proximal the axial center of the upper plate when the
upper plate is installed in its upper plate receptacle 113.
In a similar example, the upper plate defines an open channel
across its back side opposite its cooking surface, wherein the open
channel (such as defining a dovetail cross-section) extends
laterally from an edge of the plate to its axial center; and the
griddle module includes a beam (e.g., of a dovetail cross-section)
exceeding from the upper plate receptacle 113 (or from the hub) and
terminating in a temperature sensor 114. In this example, the beam
can be inserted into the dovetail slot in the upper plate as the
upper plate is installed in its corresponding upper plate
receptacle 113. In this and the foregoing examples, the beam can
include a conductive spring tip extending from the temperature
sensor 114, and the conductive spring tip can absorb variations in
location of the plate relative to the beam over time to maintain
sufficient thermal contact between a surface of the upper plate and
the temperature sensor 114 during operation.
In yet another example, an upper plate receptacle (or the hub)
includes an external beam cantilevered over and sprung downward
toward the back side of an upper plate when the upper plate is
installed on the hub, as shown in FIG. 4. In this example, the
system 100 can include a temperature sensor 114 supported on a
distal end of the beam and configured to contact the back surface
of the upper plate when the upper plate is installed in its
corresponding upper plate receptacle. For example, the beam can be
of aluminum, of a polymer, or of any other material exhibiting
relatively low ferromagnetism and relatively low ferrimagnetism
such that the beam--cantilevered between the upper plate and an
adjacent coil--is not substantially heated by an oscillating
magnetic field output by the adjacent coil, such as by Joule
heating. The beam can also be of a substantially minimal
cross-section to reduce absorption of the magnetic field output by
the adjacent coil, and the beam can include a thermal break (e.g.,
a polymer insert) arranged between a structural component of the
beam and the temperature sensor 114 to thermally isolate the
temperature sensor 114 from the structural component of the beam.
In this example, the temperature sensors 114 can be similarly
cantilevered off the upper induction heads or supported directly by
the base. However, the system 100 can include a temperature sensor
114 supported over the back surface of an upper plate and
configured to output a signal corresponding to the temperature of
the back surface of the upper plate, and the temperature sensor 114
can be fixed relative to the upper plate (e.g., coupled to the hub)
and can move with the upper plate as the hub rotates, or the
temperature sensor 114 can be fixed relative to the base and can
output signals corresponding to temperatures of adjacent upper
plates as the hub rotates during operation.
In another implementation, induction stations in the system 100
include contactless temperature sensor 114 that remotely detects
the temperature of an upper plate in the griddle module and outputs
a signal accordingly. In one example implementation, each griddle
module includes a laser or infrared contactless temperature sensor
114, and each coil in each induction station defines a window
through its approximate center. In this example implementation, a
contactless temperature sensor 114 can be directed through a window
in an upper coil of the induction station and can output a signal
corresponding to the temperature of the back surface of the upper
plate of a griddle module currently in the induction station.
Similarly, a contactless temperature sensor 114 can sense the
temperature of an adjacent lower plate through the barrier via a
window through the center of the lower coil. In this example
implementation, the material of the non-magnetic window of the
upper induction head and the material of the barrier of the base
can be substantially transparent to electromagnetic radiation
within a relatively narrow wavelength band, and the temperature
sensors 114 can include laser or infrared contactless temperature
sensors configured to operate within this same wavelength band.
In this variation, the system 100 can include one contact-based or
contactless temperature sensor for each upper plate and lower plate
in each griddle module. For example, for a system with five
induction stations and five griddle modules, the system 100 can
include ten temperature sensors 114, such as one temperature sensor
114 integrated into each of the five upper plates and lower plates
and electrically coupled to sensor lead receptacles in the hub. In
this example, all ten temperature sensors 114 can be substantially
identical and arranged within the system 100 in substantially the
same way (e.g., integrated into or separate from and cantilevered
toward a corresponding plate). Alternatively, the system 100 can
include different types of temperature sensors, such as five
contactless (e.g., infrared) lower temperature sensors 114 arranged
within the base and configured to output signals corresponding to
the temperatures of adjacent lower plates and five contact-based
upper temperature sensors 114 cantilevered off of the hub,
contacting the back surfaces of the upper plate receptacles, and
configured to output signals corresponding to temperatures of upper
plates.
In the foregoing variations in which the system 100 includes
temperature sensors 114 integrated into plates or supported off of
the hub or plate receptacles, the system 100 can further include a
slip ring assembly 144--as shown in FIGS. 4 and 6--arranged between
the hub and the base and configured to communicate signals from the
temperature sensors 114 into the base, such as to the controller
180 arranged within the base. For example, for the system 100 that
includes five griddle modules, five induction stations, five upper
plates, five lower plates, and ten temperature sensors 114, the hub
can include a slip ring assembly including one ground ring and ten
sense rings, including one sensing ring per temperature sensor 114
configured to communicate an analog temperature signal from a
temperature sensor 114 to the controller 180 in the base.
Alternatively, the system 100 can include a signal processing unit
(SPU) arranged within the hub, and the SPU can sample each of these
temperature sensors 114, transform analog temperature signals into
digital temperature values, and then transmit these digital
temperature values via a limited number of channels (e.g.,
low-current data lines) in the slip ring assembly to the controller
180. For example, in this implementation, the slip ring assembly
can include one ground ring, one power ring to supply power to the
SPU, and one or more data rings over which the SPU transmits
digital temperature values for all temperature sensors 114 into the
base (e.g., over I2C communication protocol).
In a similar implementation, the system 100 includes a wireless
transmitter arranged within the hub, coupled to the SPU, and
configured to wirelessly broadcast digital temperature values from
the SPU to a remote wireless receiver, such as within the base and
electrically coupled to the controller 180. In this implementation,
the SPU and the wireless transmitter can be powered by a
rechargeable battery (or a one-time use sealed battery) transiently
installed within the hub. Alternatively, the wireless transmitter
and the SPU can be powered by an inductive energy harvester
arranged within or coupled to the hub, configured to harvest energy
from a magnetic field output by dedicated inductive coil in the
base or in an upper induction head or to siphon energy from
magnetic fields output by coils in the induction stations, and to
condition (e.g., rectify) this energy to power the wireless
transmitter and/or to charge a battery in the hub while the system
100 is in operation.
16. Controller and Temperature Control
As shown in FIG. 5, one variation of the system 100 includes a
controller 180 configured to control the positions of a griddle
module in the induction stations via the hub actuator and to
control the power output of coils in the induction stations during
a cook cycle. For example, the controller 180 can modulate power
outputs of upper and lower coils in the induction stations based on
a position of the griddle module and a temperature value received
from the temperature sensors in order to achieve a target heat flux
into a food product, to achieve a target temperature of the food
product, and/or to achieve a target temperature or temperature
profile of the upper and lower plates of the griddle module
containing the food product corresponding to a doneness value
selected for the food product.
In this variation, the system 100 can be configured to cook a food
product to a single doneness value (e.g., "medium" or
"medium-well") corresponding to a total target heat flux through
the upper and lower plates in a griddle module, calculated as the
sum of the integral of temperatures of the upper plate of the
griddle module and the integral of temperatures of the
corresponding lower plate during a cook cycle. The controller 180
can also calculate or implement a total target intra-station heat
flux, such as calculated by multiplying the total target heat flux
by the intra-station period and dividing this product by the total
time of a cook cycle. Thus, during a cook cycle, the controller 180
can sample temperature sensors coupled to or integrated into the
upper and lower plates of a griddle module containing a food
product, such as at a rate of 1 Hz; during each intra-station
period in which the griddle module is positioned within an
induction station, the controller 180 can implement closed-loop
feedback controls to modulate the power outputs of coils in the
induction station to achieve the total target intra-station heat
flux upon expiration of the intra-station period and before
shifting the griddle module forward to a next induction station.
The controller 180 can thus independently control power outputs of
each coil in each induction station to achieve a total target heat
flux through the upper and lower plates of a griddle module during
a cook cycle to achieve a single doneness value of a food
product.
The controller 180 can also store multiple discrete doneness values
for food products. For example, the controller 180 can store
discrete preset total target heat flux values (and/or preset target
intra-station heat flux values) for each of "rare," "medium-rare,"
"medium," "medium-well," and "well-done" doneness values. In one
example in which the system 100 is integrated into an automated
foodstuff assembly apparatus, the automated foodstuff assembly
apparatus 200 can receive a hamburger order from a patron, wherein
the hamburger order specifies a doneness--selected from the
foregoing set of five available doneness values--for a hamburger
patty. In this example, the controller 180 receives a request to
prepare a hamburger patty of this doneness value from the automated
foodstuff assembly apparatus 200 and then selects a total target
heat flux value (and/or target intra-station heat flux value)
corresponding to this specified doneness for the hamburger patty.
Once an adjacent grinder system grinds, presses, and dispenses a
new hamburger patty onto the lower plate of a griddle module in the
entry induction station, the controller 180 modulates the outputs
of the upper and lower coils of the entry induction station to
achieve the target intra-station heat flux value at the induction
station during a first intra-station period; the controller 180
then repeats this process for each intermediate induction station
and for the exit induction station to produce a hamburger patty at
the specified doneness upon conclusion of the cook cycle; the
system 100 then releases the cooked hamburger patty to a hamburger
bun, box, plate, or other container in Block S162.
Alternatively, the controller 180 can implement a parametric model
to calculate total target heat flux values (and/or target
intra-station heat flux values) for quantitative (e.g., rather than
qualitative) doneness values selected from a continuum of
quantitative doneness values. In one example shown in FIG. 8, a
patron can generate a hamburger order within an ordering interface
executing on a mobile computing device (e.g., a smartphone) or at a
local kiosk connected to the automated foodstuff assembly
apparatus; within the ordering interface, the patron can manipulate
a slider along a slider bar to select a doneness value for a
hamburger patty in the patron's hamburger order, such as
quantitative doneness value between 1 and 100 along a 100-increment
slider bar. Upon receipt of this hamburger order, the automated
foodstuff assembly apparatus 200 can distribute a request for a new
hamburger patty--cooked to the selected doneness value--to the
controller 180, and the controller 180 can calculate the total
target heat flux value and/or target intra-station heat flux value
for the hamburger patty by passing the selected quantitative
doneness value into a parametric model. The controller 180 can then
modulate the power outputs of coils in the induction stations
throughout a cook cycle to achieve the total target heat flux value
and/or target intra-station heat flux value for the hamburger patty
before releasing the cooked hamburger patty in Block S162 for
assembly with other ingredients specified in the patron's hamburger
order.
The system 100 can also be configured to receive food products of
different sizes in Block S112, and the controller 180 can select
and implement a total target heat flux value and/or a preset target
intra-station heat flux value for a food product based on its size.
For example, the system 100 can receive hamburger patties from a
grinder system in Block S112, wherein the grinder system is
configured to grind and press patties of two different sizes, such
as one-quarter-pound and one-half-pound hamburger patties; and the
controller 180 can select a preset total target heat flux value
and/or a preset target intra-station heat flux value for a
hamburger patty based on a size of the hamburger patty such as
either a first heat flux for one-quarter-pound hamburger patties or
a second heat flux less than the first heat flux for one-half-pound
hamburger patties.
Similarly, the system 100 can also be configured to receive food
products of different types in Block S112, and the controller 180
can select and implement a preset total target heat flux value
and/or a preset target intra-station heat flux value for a food
product based on its types. For example, a grinder system can be
configured to grind 100% beef hamburger patties, 100% turkey
hamburger patties, and 50% beef/50% turkey hamburger patties; and
the controller 180 can select a preset total target heat flux value
and/or a preset target intra-station heat flux value for a
hamburger patty based on its composition, such as including a first
heat flux for 100% beef hamburger patties, a second heat flux less
than the first heat flux for 50% beef/50% turkey hamburger patties,
and a third heat flux less than the second heat flux for 100%
turkey hamburger patties.
The controller 180 can additionally or alternatively select a
preset total target heat flux value and/or a preset target
intra-station heat flux value for a food product based on the fat
content (or protein content, etc.) of the food product. For
example, the controller 180 can access nutritional data entered
from a container of meat loaded into the adjacent grinder system
for an average or actual fat content of this volume of meat and
then select a preset total target heat flux value and/or a preset
target intra-station heat flux value for hamburger patties formed
from this volume of meat. In this example, the automated foodstuff
assembly apparatus 200 can include a scanner (e.g., a barcode
scanner, an RFID scanner) configured to retrieve data from a
container of meat loaded into the grinder system, can interface
with an external (e.g., a handheld) scanner to access such data
scanned from the container, can receive a meat type and/or meat
data (e.g., fat content, protein content) entered manually by an
operator through an integrated or connected user interface, or
access these data in any other way, and the controller 180 can then
implement a first heat flux for hamburger patties with 10% fat
content and can implement a second heat flux greater than the first
heat flux for hamburger patties with 20% fat content.
Similarly, the controller 180 can select a preset total target heat
flux value and/or a preset target intra-station heat flux value for
a food product based on a level of compaction or density of the
food product. For example, the grinder can be configured to compact
ground meat to one of two compaction levels to form a hamburger
patty, such as a loose compaction for rare hamburger patties and a
tight compaction for well-done hamburger patties. In this example,
the controller 180 can: select a first intra-station heat flux
value for a loose compaction patty assigned a rare doneness value;
select a second intra-station heat flux value greater than the
first intra-station heat flux value for a loose compaction patty
assigned a medium-rare doneness value; select a third intra-station
heat flux value for a tight compaction patty assigned a medium
doneness value; and select a fourth intra-station heat flux value
greater than the third intra-station heat flux value for a tight
compaction patty assigned a well-done doneness value.
The controller 180 can also select a preset total target heat flux
value and/or a preset target intra-station heat flux value for a
food product based on the initial temperature of the food product.
For example, the controller 180 can sample outputs of a temperature
sensor installed within the grinder system to determine the initial
temperature of a hamburger patty and then implement a first heat
flux for hamburger patties within a first initial temperature range
and can implement a second heat flux greater than the first heat
flux for hamburger patties within a second initial temperature
range less than the first initial temperature range. The controller
180 can implement similar methods and techniques to select a preset
total target heat flux value and/or a preset target intra-station
heat flux value for a food product based on the initial
temperatures of the upper and lower plates in a griddle module when
loaded with a new food product in Block S112.
In the foregoing implementations, the controller 180 can access and
implement one or more lookup tables containing preset total target
heat flux values and/or preset target intra-station heat flux
values for various combinations of food product sizes, selected
doneness values, food product compaction level or density, food
product compositions, initial food product temperatures, initial
upper and lower plate temperatures, etc., as shown in FIG. 8.
Alternatively, the system 100 can implement one or more parametric
models to determine an intra-station target heat flux for a food
product. For example, the controller 180 can pass a hamburger patty
size, a selected doneness value, an intra-grinder compaction value,
a hamburger patty composition (e.g., meat type, fat content,
protein content), a hamburger patty compaction level or density, an
initial hamburger patty temperature, and/or initial upper and lower
plate temperatures, etc. directly into a parametric module to
calculate an intra-station target heat flux for a new hamburger
patty before or as the hamburger patty is loaded into a griddle
module in the entry induction station in Block S112. Thus, in this
example, the system 100 can implement a parametric model to
calculate target temperatures of the first lower plate and the
first upper plate at each of the entry induction station, the
intermediate induction station, and the exit induction station
based on a fat and protein composition of the first food product
including a ground meat patty, a compaction value of the first food
product, an initial temperature of the first food product, and a
duration of the cook cycle or intra-station period. Alternatively,
the controller 180 can pass one or more of the foregoing parameters
into one or more lookup tables to retrieve corresponding
coefficients and then pass these coefficients into a parametric
model to calculate an intra-station target heat flux for a food
product.
In the foregoing implementations, the controller 180 can also
select or calculate induction station-specific intra-station target
heat flux values for a food product. For example, the controller
180 can select and implement a high heat flux value for the entry
induction station to sear the top and bottom of a hamburger patty
during the first intra-station period of a cook cycle and then
select and implement lower heat flux values for the intermediate
and exit induction stations to cook the hamburger patty through its
thickness before releasing the hamburger patty in Block S162, as
shown in FIG. 8. The controller 180 can thus select or calculate a
target heat flux over a static intra-station period at each
induction station to heat or cook a food product to a selected
doneness for the food product over the course of a cook cycle.
Furthermore, the controller 180 can translate an intra-station
target heat flux into a single target temperature or a sequence of
target temperatures for the upper and lower plates of a griddle
module throughout a cook cycle, as shown in FIG. 8, and the
controller 180 can implement closed-loop feedback techniques to
modulate the power outputs of the upper and lower coils of the
induction stations in order to achieve these target temperatures in
the upper and lower plates of the griddle module. In this
variation, the method 100 can include: calculating target
temperatures of the first lower plate and the first upper plate at
each of the entry induction station, the intermediate induction
station, and the exit induction station based on a doneness value
assigned to the first food product in Block S170; tracking actual
temperatures of the first lower plate and the first upper plate in
the first griddle module between the first period of time and the
sixth period of time in Block S172; and modulating power outputs of
lower coils and upper coils of the entry induction station, the
intermediate induction station, and the exit induction station
based on differences between the target temperatures and the actual
temperatures of the first lower plate and the first upper plate in
Blocks S120, S122, and S124, etc., and the controller 180 can
implement these Blocks of the method 100 throughout a cook
cycle.
The controller 180 can thus modulate the power outputs of the upper
and lower coils of the induction station--thereby controlling a
heat flux from the upper and lower plates of a griddle
module--during a cook cycle based on outputs of a temperature
sensor thermally coupled to the upper and lower plates, a doneness
value specified for a food product, and/or various other measured
or entered parameters throughout a cook cycle of static duration,
as shown in FIG. 8. The controller 180 can additionally or
alternatively vary the duration of a cook cycle or an intra-station
period to cook a food product to a specified doneness. For example,
the controller 180 can immediately open a griddle module upon entry
into the exit induction station in Block S160 and trigger the
retrieval system to retrieve a food product contained therein in
Block S162 if the food product is assigned a rare doneness level;
and the controller 180 can supply power to the upper and lower
coils of the exit induction station for a full intra-station
duration before triggering the retrieval system to retrieve a food
product contained therein in Block S162 if the food product is
assigned a well-done doneness level.
For the system 100 that includes multiple griddle modules, the
controller 180 can simultaneously and independently control the
power outputs of each induction station module to achieve a target
heat flux (or target plate temperatures) at each griddle module
during each intra-station period in order to cook each food product
to a specified doneness level independent of other food products
simultaneously in process in the system 100. For example, the
controller 180 can implement methods and techniques described above
to simultaneously process a rare hamburger patty, a medium-rare
hamburger patty, a medium hamburger patty, a medium-well hamburger
patty, and a well-done hamburger patty.
For example, the controller 180 can execute the foregoing Blocks of
the method 100 for each griddle module and induction station in the
system 100 and can repeat this process as the hub conveyor moves
griddle modules through sequential induction stations in order to
achieve a target doneness for each hamburger patty exiting the
system 100. In this example, the controller 180 can receive an
order for a hamburger patty, including a doneness specification for
the hamburger patty, and the controller 180 can select a
temperature profile for the hamburger patty based on the doneness
specification. In this example, a temperature profile can be
specific to a particular doneness specification and can define a
target temperature of the upper and lower plates at each induction
station, such as based on the intra-station period and a known
transition time between induction stations. In this example, a
temperature profile can also define a peak target temperature for
the upper and lower plates of a griddle module when the griddle
module is arranged within the entry induction station, and the
temperature profile can define a minimum temperature of the upper
and lower plates when the griddle module is arranged in the exit
induction station such that the upper and lower plates can be
quickly and actively heated to a new peak temperature specific to a
temperature profile of a subsequent hamburger patty to be loaded
into the griddle module once the griddle module is advanced into
the entry station, thereby reducing or eliminating a wait time for
the upper and lower plates to cool to an entry target temperature
when the griddle module releases a well-done patty and prepares to
receive a new patty with a `rare` specification.
However, the controller 180 can implement any other controls or
techniques to control the power outputs of coils in the induction
stations.
17. Dynamic Plate Offset
In one variation shown in FIG. 7, the method 100 includes Block
S180, which recites, calculating a compression distance for the
first food product based on the doneness value assigned to the
first food product, and Block S182, which recites driving a
compression actuator 128 coupled to the upper coil in the
intermediate induction station to a target position corresponding
to the compression distance in order to set a maximum compression
of the first food product between the first lower plate and the
first upper plate in the intermediate induction station. Generally,
in this variation, the controller 180 can calculate a target
compression distance for a product based on a doneness value
selected for or assigned to the food product and can drive an
elevation actuator 127 (or a compression actuator 128, as described
below) to a target vertical position corresponding to the target
compression distance for the food product in order to control a
cook rate of the food product.
In this variation, a griddle module includes a compression actuator
128 that functions to adjust an offset height between opposing
cooking surfaces of the upper and lower plates of a griddle module.
In particular, by actively compressing the upper and lower plates
of a griddle module, the system 100 can cook a food product at an
increased rate. Similarly, by lowering a stop between the upper and
lower plates of the griddle module and permitting the upper plate
to compress a food product below, the system 100 can cook a food
product at an increased rate. The system 100 can therefore actively
compress the upper plate of a griddle module or control the
position of a lower stop for the upper plate in the griddle module
in order to control the cook rate of a food product loaded into the
griddle module.
In one implementation in which an upper plate receptacle includes a
skid 116 configured to couple to an adjacent upper induction head
and in which the system 100 includes an elevation actuator 127
configured to set the vertical position of the upper induction
head, the elevation actuator 127 can shift the vertical position of
the upper induction head to a position corresponding to a minimum
offset distance between the opposing cooking surfaces of the upper
and lower plates of the adjacent griddle module. For example, if
the minimum offset distance between the opposing cooking surfaces
of the upper and lower plates of the griddle module is less than
the current thickness of the food product, the weight of the upper
plate and upper plate receptacle can draw the upper plate downward
to compress the food product onto the skid 116 bottom on the upper
induction head, thereby setting a maximum compression distance for
the food product. The elevation actuator 127 can thus function as a
compression actuator 128.
In the foregoing implementation, a skid 116 extending from the
upper plate receptacle of the griddle module can thus extend up to
and over a top surface of the upper induction head and can draw the
upper plate upward (i.e., away from the lower plate) as the
elevation actuator 127 raises the upper induction head. Similarly,
when the elevation actuator 127 drops the upper induction head, the
skid 116 can lower with the upper induction head, thus lowering the
upper plate back toward the lower plate. Furthermore, once the
upper plate reaches and is supported vertically by the food product
below, the controller 180 can continue to drive the upper induction
head downward to a position corresponding to the target compression
distance; the upper induction head can thus contact the top surface
of the upper plate and force the upper plate downward, thereby
compressing the food product, as shown in FIG. 7. For example, the
upper induction head can be supported by a parallel four-bar
linkage and counterweighted (e.g., with a gas strut), and the
elevation actuator 127 can be coupled to the parallel four-bar
linkage to actively raise and lower the upper induction head such
that the upper induction head remains substantially parallel to the
barrier throughout its travel range. In another example, the upper
induction head is mounted directly to a linear actuator configured
to raise and lower the upper induction head along a vertical linear
trajectory.
The system 100 can thus receive a food product, such as in the form
of a thick hamburger patty, at a griddle module positioned in the
entry induction station in Block S112, and the controller 180 can
then adjust the height of the upper induction head of the entry
induction station to actively compress the food product to a target
thickness, as shown in FIG. 7. By compressing the upper plate onto
the food product, the system 100 can: ensure sufficient contact
between the upper plate and the food product to heat or cook the
food product within the cook cycle; and control a thickness of the
food product, which may affect the final doneness level of the food
product for a given heat flux during a cook cycle (e.g., a thicker
hamburger patty may be less done than a thinner hamburger patty
given identical cook cycles). In one implementation, the system 100
includes a single compression actuator 128 coupled to the entry
upper induction head, and the controller 180 can calculate a target
thickness for a hamburger patty loaded in a griddle module
positioned therein based on the doneness level specified for the
hamburger patty and then drive the entry induction station downward
to compress the food product to this target thickness. In this
implementation, the system 100 can exclude compression actuators
128 at other induction stations such that the upper plate of the
griddle module compresses the food product due to its own weight
when positioned in subsequent induction stations in the system 100,
and the controller 180 can thus accommodate for a number of
induction stations in the system 100, a weight of the upper plate
and upper plate receptacle, and the size (e.g., the weight) of the
hamburger patty when calculating the target thickness of the
hamburger patty in the entry induction station. Alternatively, the
system 100 can include a compression actuator 128 at the exit
induction station, and the controller 180 can implement similar
methods and techniques to calculate a final target thickness of the
hamburger patty to finish cooking the hamburger patty and can drive
the compression actuator 128 in the exit induction station to a
corresponding vertical position before the hamburger patty is
released in Block S162. Yet alternatively, the system 100 can
include compression actuators 128 at multiple induction stations,
and the controller 180 can actively set the positions of each of
these compression actuators 128 throughout a cook cycle in order to
achieve a target thickness and/or specified doneness of a food
product upon conclusion of a cook cycle.
In another implementation, the compression actuator 128 includes an
electric motor or a pneumatic cylinder that adjusts a vertical
position of a lower stop that defines a lowest available position
of an upper plate relative to its corresponding lower plate. For
example, the hub can include a lower stop configured to set a lower
travel limit of an upper plate receptacle, and the compression
actuator 128 can be mounted or coupled to the hub and can directly
adjust the vertical position of the lower stop. Similarly, the
upper plate receptacle can include a skid 116 that vertically
couples the upper plate receptacle to an upper induction head
above, the base can include a lower stop configured to set a lower
travel limit of an upper induction head, and the compression
actuator 128 can be distinct from the elevation actuator 127 and
can be configured to adjust the vertical position of this lower
stop to set a vertical position of the upper induction head during
an intra-station period.
In this variation, the controller 180 can also control the height
of an upper plate of a griddle module (e.g., by controlling the
position of a corresponding compression actuator 128 and/or a
position of the corresponding upper induction head) based on a
doneness specification for a food product loaded into the griddle
module. In one example, for a hamburger patty assigned a
`well-done` specification, the controller 180 can trigger the
compression actuator 128 to drive the upper plate toward the lower
plate of the griddle module to reduce the offset between opposing
cooking surfaces of the upper and lower plates, thereby compressing
the hamburger patty (or enabling the upper plate to lower toward
the lower plate to compress the hamburger patty), reducing the
thermal distance between the center of the patty and the upper and
lower plates, and yielding a higher center temperature in the
hamburger patty for a given cook time. In this example, for a patty
assigned a `rare` specification, the controller 180 can trigger the
compression actuator 128 to drive the upper plate of the griddle
module away from the lower plate to increase the offset distance
between the opposing cooking surfaces of the upper and lower
plates, thereby yielding a thicker patty, a greater thermal
distance between the center of the patty and an adjacent plate, and
yielding a lower center temperature for a given cook time. The
controller 180 can thus actively position the upper plate of a
griddle module or actively set a compression limit for a griddle
module throughout a cook cycle in order to achieve a doneness level
specified for a food product loaded into the griddle module.
Alternatively, a griddle module can include a mechanical or gas
spring 115 arranged between the hub and an upper plate receptacle
and configured to resist compression of a patty in the griddle
module due to the weight of the upper plate and the upper plate
receptacle assembly, as shown in FIG. 5. In particular, in this
implementation, the spring 115 can be selected for a spring 115
constant (at a typical operating temperature when the system 100 is
in operation) to achieve a target compression of a patty in the
griddle module by the weight of the upper plate and the upper plate
receptacle. For example, the system 100 can include a spring 115
arranged between an upper plate and the hub and configured to
counter compression of the first food product between the upper
plate and the lower plate due to a weight of the upper plate; and a
stop coupled to the hub and defining a lower position limit of the
upper plate relative to the lower plate.
A raw patty received at the entry induction station 121 may be
thicker than a cooked patty. Furthermore, raw patties may have a
tendency to spring back after being compressed, which can cause the
as-cooked thickness to be higher than intended. To reduce or
prevent patty spring-back, the compressor actuators 128 can be
employed to apply a constant compression force on the patty for a
predetermined amount of time during the cook cycle. This prevents
the plats 112 from binding as the patties are rotated through the
induction stations.
18. Alternative System
With reference to FIGS. 9-16, an alternative system 200 is
provided. Like the system 100, the system 200 may cook a single
patty (e.g., a meat or other food patty) or multiple patties at a
time. The system 200 may include features and functions that are
the same as or similar to some of the features and functions of the
system 100 described above, and therefore, some of such similar
features and functions may not be described again in detail. The
system 200 may include a base 202, a hub 204 (FIGS. 12 and 15), a
plurality of lower induction coils 206 (FIGS. 12 and 15), a first
upper induction head 208, a second upper induction head 210, a
third upper induction head 212, and a spatula assembly 214 (FIGS. 9
and 10). The base 202 may include an annular grease trough 216 that
surrounds a glass barrier plate 218 and the hub 204. The lower
induction coils 206 may be fixedly mounted to the base 202 below
the barrier plate 218. The lower induction coils 206 may be evenly
spaced apart from each other in a circular pattern, for
example.
As shown in FIGS. 12 and 15, the hub 204 may be a generally
disk-shaped member that is rotatably mounted to the base 202. A
motor 219 (FIG. 14) disposed beneath the base 202 may rotate the
hub 204 relative to the base 202, the barrier plate 218, the lower
induction coils 206, and the upper induction heads 208, 210, 212. A
plurality of lower cooking plates or pucks 220 may be mounted to
the hub 204 for rotation with the hub 204. The lower plates 220 are
evenly spaced apart from each other in a circular pattern having
the same diameter and center point as the lower induction coils
206.
The hub 204 may also include a plurality of wipers 222 that extend
outward the trough 216. Each of the wipers 222 may be disposed
between a different pair of the lower plates 220. The wipers 222
may be positioned such that longitudinal axes of the wipers 222 do
not intersect a rotational axis of the hub 204. The wipers 222 may
wipe the surface of the barrier 218 and push grease into the trough
216 as the hub 204 rotates relative the base 202. Distal ends of
the wipers 222 may include trough wipers 226. As shown in FIG. 13,
the trough wipers 226 may include a plurality of bristles 228 that
scrub the trough 216 and push the grease toward a drain hole 229
(FIG. 9) in the trough 216 as the hub 204 rotates relative to the
base 202. A conduit (not shown) can connect the drain hole 229 with
a waste receptacle (not shown) for disposal of the grease.
As shown in FIG. 15, a central portion of the hub 204 may include a
plurality of vertically extending posts 230. The posts 230 rotate
with the hub 204 relative to the base 202 and the upper induction
heads 208, 210, 212. A carrier 232 may be slidably mounted on each
post 230. As shown in FIG. 10, each carrier 232 includes a skid 234
that slidably contacts top surfaces of the upper induction heads
208, 210, 212. As shown in FIG. 14, each carrier 232 also includes
a bracket 236 supporting an upper cooking plate or puck 238 below
the upper induction heads 208, 210, 212. The posts 230 are arranged
in a circular pattern such that each of the upper plates 238 is
axially aligned with and disposed above a corresponding one of the
lower plates 220. The lower and upper plates 220, 238 are
rotationally fixed relative to each other, but the upper plates 238
are axially movable relative to the lower plates 220. That is, the
carriers 232 (to which the upper plates 238 and the skids 234 are
mounted) are slidable up and down along the posts 230.
As shown in FIG. 9, the first upper induction head 208 houses a
first upper induction coil 240. As shown in FIG. 10, an actuator
242 may move the first upper induction head 208 vertically up and
down relative to the base 202. The actuator 242 may include a tower
244, a motor 246, and a block 248. The tower 244 may be fixedly
mounted to the base 202 and may extend vertically upward from the
base 202. The block 248 may be movably mounted on the tower 244.
The first upper induction head 208 may be fixed to the block 248.
The motor 246 may be mounted on the tower 244 and is operable to
selectively drive the block 248 and the first upper induction head
208 vertically up and down the tower 244. As described above, one
of the skids 234 contacts a top surface of the first upper
induction head 208. Therefore, when the actuator 242 moves the
first upper induction head 208 upward away from the base 202, the
skid 234 (and the carrier 232 and upper plate 238) are forced
upward with the first upper induction head 208. Similarly, when the
actuator 242 moves the first upper induction head 208 downward
toward the base 202, the skid 234, carrier 232, and upper plate 238
are allowed to move downward with the first upper induction head
208.
As shown in FIG. 9, the second upper induction head 210 may house a
second upper induction coil 250, a third upper induction coil 252,
and a fourth upper induction coil 254. In other embodiments, the
second upper induction head 210 may house fewer or more than three
upper induction coils. As shown in FIGS. 9 and 11, one lateral end
of the second upper induction head 210 may be mounted on a rotating
support member 256 and another lateral end of the second upper
induction head 210 may releasably engage a latching support member
258. The rotating support member 256 and the latching support
member 258 support the second upper induction head 210 at a
constant height above the base 202, hub 204, and lower plates 220.
To facilitate cleaning, repairs and maintenance, the latching
support member 258 can include a latch that can be actuated to
release the second upper induction head 210 to allow the second
upper induction head 210 to rotate about a vertically extending
rotational axis defined by the rotating support member 256.
The third upper induction head 212 houses a fifth upper induction
coil 260 (FIG. 9). As shown in FIG. 10, an actuator 262 may move
the third upper induction head 212 vertically up and down relative
to the base 202. Like the actuator 242, the actuator 262 may
include a tower 264, a motor 266, and a block 268. The tower 244
may be fixedly mounted to the base 202 and may extend vertically
upward from the base 202. The block 268 may be movably mounted on
the tower 264. The third upper induction head 212 may be fixed to
the block 268. The motor 266 may be mounted on the tower 264 and is
operable to selectively drive the block 268 and the third upper
induction head 212 vertically up and down the tower 264. As
described above, one of the skids 234 contacts a top surface of the
third upper induction head 2012. Therefore, when the actuator 262
moves the third upper induction head 212 upward away from the base
202, the skid 234 (and the carrier 232 and upper plate 238) are
forced upward with the third upper induction head 212. Similarly,
when the actuator 262 moves the third upper induction head 212
downward toward the base 202, the skid 234, carrier 232, and upper
plate 238 are allowed to move downward with the third upper
induction head 212.
The first, second, and third upper induction heads 208, 210, 212
define a plurality of cooking stations. That is, the first upper
induction head 208 defines a first cooking station (or an entry or
input cooking station) at the first upper induction coil 240; the
second upper induction head 210 defines second, third, and fourth
cooking stations (or intermediate cooking stations) at the second,
third and fourth upper induction coils 250, 252, 254; and the third
upper induction head 212 defines a fifth cooking station (or an
exit or output cooking station) at the fifth upper induction coil
260. The motor 219 (FIG. 14) can selectively rotate the hub 204 to
move the lower plates 220 and the upper plates 238 in a
counterclockwise direction relative to the upper induction coils
240, 252, 254, 256, 260 among the plurality of cooking stations. It
will be appreciated that while the system 200 shown in the figures
includes five cooking stations, in some embodiments, the system 200
could include fewer or more than five cooking stations.
To cook a patty using the system 200, a robotic arm (not shown) may
deliver a patty from a grinder (not shown)(or from another patty
source) to the input cooking station. That is, with the first upper
induction head 208 in a raised position (as shown in FIG. 10), the
robotic arm may dispense the patty onto the lower plate 220
positioned at the input cooking station. Once the robotic arm moves
out of the way after dispensing the patty, the actuator 242 may
move the first upper induction head 208 downward to contact the
patty with the upper plate 238 and compress the patty to a desired
thickness. The upper and lower induction coils 240, 206 at the
input cooking station can be energized to cook the patty for a
selected amount of time before the motor 219 rotates the hub 204 to
move the lower and upper plates 220, 238 counterclockwise to move
the patty sequentially to each of the intermediate cooking stations
for additional cooking for selected amounts of time. If desired,
after a patty is moved out of the input cooking station, the
robotic arm can deliver another patty to the input cooking station.
In this manner, the system 200 can cook multiple patties at the
same time.
After cooking a patty at each of the intermediate cooking stations,
the hub 204 can be rotated to move the corresponding plates 220,
238 to the output cooking station for additional cooking. An IR
(infrared) sensor 270 (FIG. 14) may be mounted to the base 202 or
to the tower 264, for example. The IR sensor 270 is positioned to
have a clear line of sight to a periphery of a patty in the output
cooking station and can sense a temperature of the periphery of the
patty to determine whether or not the patty has been cooked to a
selected doneness.
If the patty temperature sensed by the IR sensor 270 indicates that
the patty is sufficiently cooked, the actuator 262 can move the
third upper induction head 212 from the lowered position (shown in
FIG. 10) to the raised position (shown in FIG. 14). With the third
upper induction head 212 in the raised position, a proximity sensor
272 (FIG. 12) may project a beam of light 274 (FIG. 14) onto the
patty to detect a position of the patty on the lower plate 220. The
proximity sensor 272 can be mounted a housing of a first actuator
276 of the spatula assembly 214, for example. In some embodiments,
a thermal camera could replace the proximity sensor 272. The
thermal camera could sense the temperature of the patty after the
patty is cooked at the output cooking station. The thermal camera
could also be used to determine the position of the patty on the
lower plate 220 (e.g., whether or not the patty is centered on the
lower plate 220 and/or how far off center the patty is on the lower
plate 220). In some embodiments, another thermal camera could be
positioned to determine the temperature and/or position of a patty
on the lower plate 220 at the input cooking station. In some
embodiments, a proximity sensor (like the proximity sensor 272)
could be positioned to detect the position of the patty at the
input cooking station. In some embodiments, a proximity sensor
(like the proximity sensor 272) could be positioned to detect
whether a patty at the output cooking station has been picked up by
the spatula assembly 214. If the proximity sensor does not detect a
patty on the spatula assembly 214, the control module may trigger
an alert for an operator to inspect the system.
With the third upper induction head 212 in the raised position, the
first actuator 276 may move the spatula assembly 214 to the output
cooking station to pick up and remove the patty from the output
cooking station and carry the patty to a food assembly station (not
shown). As shown in FIG. 15, a backstop member 278 may be disposed
at the output cooking station between the lower and upper plates
220, 238 at the output cooking station. The backstop member 278 may
be fixedly attached to the base 202 or to the tower 264 of the
actuator 262, for example. As shown in FIGS. 15 and 16, the
backstop member 278 may be an elongated beam having a concave
curved portion 280. The concave curved portion 280 may be
positioned relative to the lower plate 220 at the output cooking
station such that the concave curved portion 280 will prevent a
patty from sliding off the lower plate 220 while a spatula 282 of
the spatula assembly 214 is being slid underneath the patty to pick
up the patty for removal from the output cooking station.
As shown in FIG. 16, the backstop member 278 may also include a
lower wiper 284 and an upper wiper 286. The lower wiper 284 may
extend downward from the backstop member 278, and the upper wiper
286 may extend upward from the backstop member 278. The lower and
upper wipers 284, 286 can be formed from a silicone, for example,
or from any other suitable (e.g., heat-resistant and non-porous)
polymeric material. The lower and upper wipers 284, 286 can be
discrete parts or integrally formed as a single piece.
Once the spatula assembly 214 has removed the patty from the output
cooking station, the third upper induction head 212 can be moved
back to the lowered position, and then the hub 204 can be rotated
to move the lower and upper plates 220, 238 from the output cooking
station to the input cooking station. As the plates 220, 238 move
from the output cooking station to the input cooking station, the
lower and upper wires 284, 286 on the backstop member 278 may wipe
grease and/or other debris from the plates 220, 238.
As shown in FIGS. 10 and 15, the spatula assembly 214 may include
the first actuator 276 (e.g., a motor), a hub 288, a second
actuator 290, a first arm 292, a second arm 294, and the spatula
282. The first actuator 276 may be mounted to a fixed structure
(e.g., to the tower 264 or to a wall of an enclosure in which the
system 200 is mounted). The hub 288 may be attached to an output
shaft 296 of the first actuator 276 and may rotatable about a first
rotational axis A1 (defined by the output shaft 296). The second
actuator 290 may be housed within the hub 288 and may be connected
to one end of the first arm 292 to rotate the first arm 292
relative to the hub 288 about a second rotational axis A2 that is
perpendicular to the first rotational axis A1. The second arm 294
may be rotatable connected to the other end of the first arm 292. A
linkage may be housed within the first arm 292 and may couple a
first shaft (e.g., a shaft connecting the first arm 292 with the
second actuator 290) and a second shaft (e.g., a shaft connecting
the first arm 292 with the second arm 294) so that rotational of
the first arm 292 about the second rotational axis will cause
corresponding rotation of the second arm 294 about a third
rotational axis A3 that is parallel to and offset from the second
rotational axis A2. The linkage allows the spatula 282 to stay
level to the ground (i.e., stay in a horizontal orientation)
regardless of rotation of the first arm 292 about the second
rotational axis. In this manner, a patty is prevented from sliding
off of the spatula during rotation of the first arm 292 about the
second rotational axis.
To pick up a patty from the output cooking station, the first
actuator 276 can rotate the hub 288, first and second arms 292,
294, and the spatula 282 about the first rotational axis A1 to move
the spatula 282 over the lower plate 220 at the output cooking
station. The second actuator 290 can then move the first and second
arms 292, 294 and spatula 282 downward so that the spatula can be
slid underneath the patty. Thereafter, the first and second
actuators 276, 290 can move the spatula 82 and patty to a desired
location (e.g., to a food assembly station).
As shown in FIG. 15, a tower 300 may be mounted to the center of
the hub 204. The tower 300 may include a plurality of connectors
302 that electrically connect a circuit board disposed within the
tower 300 with wires extending from temperature sensors attached to
or embedded in the lower and upper plates 220, 238. Additional
wires connected to the circuit board may extend from a top end of
the tower to a slip ring (or rotary electrical interface) 304 (FIG.
10) mounted above the tower 300. As shown in FIG. 10, an annular
cap 306 may be attached to top ends of the posts 230 and may
support the slip ring 304 above the tower 300. Spring-loaded
pulleys 308 may extend downward from the cap 306 and may route the
wires from the upper plates 220, 238 to the connectors 302. A body
310 of the slip ring 304 may rotate with the cap 306, posts 230 and
hub 204 relative to a protrusion 312 of slip ring 304.
The protrusion 312 of the slip ring 304 may be attached to a fixed
structure to which the system 200 is mounted and may transmit
electrical signals from the circuit board in the tower 300 to a
controller (not shown; like the controller 180 described above).
The controller may communicate with and control the induction
coils, the motors, actuators and sensors of the system 200.
It will be appreciated that although the particular example of the
system 200 shown in the figures has five induction cooking stations
arranged in a circular pattern, in some embodiments, the system 200
could be configured to include resistance heating elements instead
of the induction coils. Additionally or alternatively, in some
embodiments, the system 200 could be configured such that the
cooking stations are arranged in a linear pattern, a U-shaped
pattern, or any other pattern.
OVERALL
The foregoing description is merely illustrative in nature and is
in no way intended to limit the disclosure, its application, or
uses. The broad teachings of the disclosure can be implemented in a
variety of forms. Therefore, while this disclosure includes
particular examples, the true scope of the disclosure should not be
so limited since other modifications will become apparent upon a
study of the drawings, the specification, and the following claims.
It should be understood that one or more steps within a method may
be executed in different order (or concurrently) without altering
the principles of the present disclosure. Further, although each of
the embodiments is described above as having certain features, any
one or more of those features described with respect to any
embodiment of the disclosure can be implemented in and/or combined
with features of any of the other embodiments, even if that
combination is not explicitly described. In other words, the
described embodiments are not mutually exclusive, and permutations
of one or more embodiments with one another remain within the scope
of this disclosure.
Spatial and functional relationships between elements (for example,
between modules, circuit elements, semiconductor layers, etc.) are
described using various terms, including "connected," "engaged,"
"coupled," "adjacent," "next to," "on top of," "above," "below,"
and "disposed." Unless explicitly described as being "direct," when
a relationship between first and second elements is described in
the above disclosure, that relationship can be a direct
relationship where no other intervening elements are present
between the first and second elements, but can also be an indirect
relationship where one or more intervening elements are present
(either spatially or functionally) between the first and second
elements.
As used herein, the phrase at least one of A, B, and C should be
construed to mean a logical (A OR B OR C), using a non-exclusive
logical OR, and should not be construed to mean "at least one of A,
at least one of B, and at least one of C." The term subset does not
necessarily require a proper subset. In other words, a first subset
of a first set may be coextensive with (equal to) the first
set.
In the figures, the direction of an arrow, as indicated by the
arrowhead, generally demonstrates the flow of information (such as
data or instructions) that is of interest to the illustration. For
example, when element A and element B exchange a variety of
information but information transmitted from element A to element B
is relevant to the illustration, the arrow may point from element A
to element B. This unidirectional arrow does not imply that no
other information is transmitted from element B to element A.
Further, for information sent from element A to element B, element
B may send requests for, or receipt acknowledgements of, the
information to element A.
In this application, including the definitions below, the term
"module" or the term "controller" may be replaced with the term
"circuit." The term "module" may refer to, be part of, or include:
an Application Specific Integrated Circuit (ASIC); a digital,
analog, or mixed analog/digital discrete circuit; a digital,
analog, or mixed analog/digital integrated circuit; a combinational
logic circuit; a field programmable gate array (FPGA); a processor
circuit (shared, dedicated, or group) that executes code; a memory
circuit (shared, dedicated, or group) that stores code executed by
the processor circuit; other suitable hardware components that
provide the described functionality; or a combination of some or
all of the above, such as in a system-on-chip.
The module may include one or more interface circuits. In some
examples, the interface circuit(s) may implement wired or wireless
interfaces that connect to a local area network (LAN) or a wireless
personal area network (WPAN). Examples of a LAN are Institute of
Electrical and Electronics Engineers (IEEE) Standard 802.11-2016
(also known as the WIFI wireless networking standard) and IEEE
Standard 802.3-2015 (also known as the ETHERNET wired networking
standard). Examples of a WPAN are the BLUETOOTH wireless networking
standard from the Bluetooth Special Interest Group and IEEE
Standard 802.15.4.
The module may communicate with other modules using the interface
circuit(s). Although the module may be depicted in the present
disclosure as logically communicating directly with other modules,
in various implementations the module may actually communicate via
a communications system. The communications system includes
physical and/or virtual networking equipment such as hubs,
switches, routers, and gateways. In some implementations, the
communications system connects to or traverses a wide area network
(WAN) such as the Internet. For example, the communications system
may include multiple LANs connected to each other over the Internet
or point-to-point leased lines using technologies including
Multiprotocol Label Switching (MPLS) and virtual private networks
(VPNs).
In various implementations, the functionality of the module may be
distributed among multiple modules that are connected via the
communications system. For example, multiple modules may implement
the same functionality distributed by a load balancing system. In a
further example, the functionality of the module may be split
between a server (also known as remote, or cloud) module and a
client (or, user) module.
Some or all hardware features of a module may be defined using a
language for hardware description, such as IEEE Standard 1364-2005
(commonly called "Verilog") and IEEE Standard 1076-2008 (commonly
called "VHDL"). The hardware description language may be used to
manufacture and/or program a hardware circuit. In some
implementations, some or all features of a module may be defined by
a language, such as IEEE 1666-2005 (commonly called "SystemC"),
that encompasses both code, as described below, and hardware
description.
The term code, as used above, may include software, firmware,
and/or microcode, and may refer to programs, routines, functions,
classes, data structures, and/or objects. The term shared processor
circuit encompasses a single processor circuit that executes some
or all code from multiple modules. The term group processor circuit
encompasses a processor circuit that, in combination with
additional processor circuits, executes some or all code from one
or more modules. References to multiple processor circuits
encompass multiple processor circuits on discrete dies, multiple
processor circuits on a single die, multiple cores of a single
processor circuit, multiple threads of a single processor circuit,
or a combination of the above. The term shared memory circuit
encompasses a single memory circuit that stores some or all code
from multiple modules. The term group memory circuit encompasses a
memory circuit that, in combination with additional memories,
stores some or all code from one or more modules.
The term memory circuit is a subset of the term computer-readable
medium. The term computer-readable medium, as used herein, does not
encompass transitory electrical or electromagnetic signals
propagating through a medium (such as on a carrier wave); the term
computer-readable medium may therefore be considered tangible and
non-transitory. Non-limiting examples of a non-transitory
computer-readable medium are nonvolatile memory circuits (such as a
flash memory circuit, an erasable programmable read-only memory
circuit, or a mask read-only memory circuit), volatile memory
circuits (such as a static random access memory circuit or a
dynamic random access memory circuit), magnetic storage media (such
as an analog or digital magnetic tape or a hard disk drive), and
optical storage media (such as a CD, a DVD, or a Blu-ray Disc).
The apparatuses and methods described in this application may be
partially or fully implemented by a special purpose computer
created by configuring a general purpose computer to execute one or
more particular functions embodied in computer programs. The
functional blocks and flowchart elements described above serve as
software specifications, which can be translated into the computer
programs by the routine work of a skilled technician or
programmer.
The computer programs include processor-executable instructions
that are stored on at least one non-transitory computer-readable
medium. The computer programs may also include or rely on stored
data. The computer programs may encompass a basic input/output
system (BIOS) that interacts with hardware of the special purpose
computer, device drivers that interact with particular devices of
the special purpose computer, one or more operating systems, user
applications, background services, background applications,
etc.
The computer programs may include: (i) descriptive text to be
parsed, such as HTML (hypertext markup language), XML (extensible
markup language), or JSON (JavaScript Object Notation), (ii)
assembly code, (iii) object code generated from source code by a
compiler, (iv) source code for execution by an interpreter, (v)
source code for compilation and execution by a just-in-time
compiler, etc. As examples only, source code may be written using
syntax from languages including C, C++, C#, Objective-C, Swift,
Haskell, Go, SQL, R, Lisp, Java.RTM., Fortran, Perl, Pascal, Curl,
OCaml, Javascript.RTM., HTML5 (Hypertext Markup Language 5th
revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext
Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash.RTM.,
Visual Basic.RTM., Lua, MATLAB, SIMULINK, and Python.RTM..
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